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Old 05-27-2013, 09:17 AM   #1
The Chimney Sweep OP
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Stainless muffler- loose baffle

The right hand silencer on my '81 R80 TIC has a really annoying from a loose baffle- when I've had it off the bike you can feel the weight of the baffle clanging around in there. I can't live with it rattling around with every tiny bump in the road!

Anyone got any advice on cutting it open and welding the thing?
or (as this seems like it might be a lot of hassle)...
Does anyone know what brand it is so I can source a replacement to match the good side?

Oh and thirdly, what kinda issues are there with running the engine as it is at the moment- with each cylinder outputting through kinda different silencers?

Here's a couple of photos for the eagle-eyed amongst you:
If photos of the cutaways and mounts will help, just give me a shout...






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Old 05-27-2013, 04:20 PM   #2
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Quote:
Originally Posted by The Chimney Sweep View Post
The right hand silencer on my '81 R80 TIC has a really annoying from a loose baffle- when I've had it off the bike you can feel the weight of the baffle clanging around in there. I can't live with it rattling around with every tiny bump in the road!

Anyone got any advice on cutting it open and welding the thing?
or (as this seems like it might be a lot of hassle)...
Does anyone know what brand it is so I can source a replacement to match the good side?

Oh and thirdly, what kinda issues are there with running the engine as it is at the moment- with each cylinder outputting through kinda different silencers?

Here's a couple of photos for the eagle-eyed amongst you:
If photos of the cutaways and mounts will help, just give me a shout...





I think you can rule out Epco and Staintune.

You could sent it to Epco for repair.

You could try cutting a slit lengthwise on the inside and see what the construction is and if you can find the lose part, then either have it welded up or braze it yourself.

I would look down the pipe with an extensded light and see what can be seen. Depending on construction you may be abl to use an expander to tighten it up.

No issues for the motor. Will hose your carb balance some so slightly rougher running.
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Old 05-27-2013, 04:29 PM   #3
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I'm pretty sure, by the looks of it, that your muffler is chrome, not stainless. That said, the finish will be ruined by cutting, and welding.
If the baffle only moves a little bit, you could try putting a couple screws through from the outside (where not visible) that could push against the baffle, keeping it from rattling.
If it is just a chrome muffler, you could probably buy a new replacement SET for less than a proper repair would cost.
Just my thoughts...
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Old 05-27-2013, 05:55 PM   #4
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Magnetic?

It looks like stainless to me.

Where are you located?

There were different ones made in England, but the ends don't look like them either. Brakewell and Greene, I think they were called. The ends don't look like any I've seen before, though the rest looks similar to both the B&G and Webbs. I don't think B&G is around any longer and neither is Webb.

If you can figure out where the baffle bulkhead is, it may be possible to drill a couple of holes and weld it together. Maybe take it to a muffler shop and see what they'd recommend.
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Old 05-27-2013, 09:00 PM   #5
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The way the end cap doesn't have the external weld showing is done by Overlander here in 73 Barries Rd
Bushfield, nr Warrnambool, Victoria
3281, Oz. (03) 5562 6362

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Old 05-28-2013, 01:55 AM   #6
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Quote:
Originally Posted by The Chimney Sweep View Post
Oh and thirdly, what kinda issues are there with running the engine as it is at the moment- with each cylinder outputting through kinda different silencers?
The only issue is you'll get a cool note out of two different wind instruments.
Reckon I have a full tone between my Overlanders.
One would need to know how it was made, to know how to fix it.
Unless one fixes things like I do.
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Old 05-28-2013, 02:10 AM   #7
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Maybe if we knew where this bloke lives and what brand the mufflers are, we could give some decent advice.
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Old 05-28-2013, 03:48 AM   #8
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Quote:
Originally Posted by Plaka View Post


You could try cutting a slit lengthwise on the inside and see what the construction is and if you can find the lose part, then either have it welded up or braze it yourself.
.
That's the way, but it could end up a big slit! And, you might miss.
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Old 05-28-2013, 04:06 AM   #9
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Originally Posted by gsd4me View Post
Maybe if we knew where this bloke lives and what brand the mufflers are, we could give some decent advice.
If he's in Oz, then he could just post it back to Overlander for a repair..probably cost less than $100 included post both ways.

His number plate looks UK ish in size though.
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Old 05-28-2013, 05:42 AM   #10
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Sorry fellas- I thought my location would display by my username...
It's a UK bike, yes and the exhausts are definitely stainless.

I've not seen photos of any other mufflers with the welding still partly showing at the outlets like this set has.

I had considered sticking a screw through to try to trap the baffle but I was concerned that any screws would just keep shaking themselves loose. As I remember the loose element is fairly weighty and can move up and down the length of them by 2-4". It has been a while since I had it off and found it rattled around! I do remember it feeling like it does locate roughly if you drop it to one end, resulting in it only being able to move a small amount until it unwedges itself.

Some of you seem pretty apprehensive over cutting and welding them...

I don't have a lot to spend, but the bike isn't a wreck (muffer dents aside!). Will a difference in backpressure/flow between the two cylinders cause issues or is the only potential problem that I have one 'variable' silencer?

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Old 05-28-2013, 03:20 PM   #11
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OK, now that we know where you are, the rest will be easy (hopefully). To repair the muffler properly it will have to be cut open, so it needs to be done properly if you want it to return to its former glory.

If it was manufactured in the UK it would be best to return it to them for proper repair.

If you don't know what the brand it, have a look in an classic bike magazine for any business that can do the job.

Maybe a forum member in the UK can help us for a suitable local repairer.
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Old 05-28-2013, 03:23 PM   #12
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Do you do stainless steel wielding?

If not take it to someone who does...

Drop it on the end to get the lose bit jammed up.

Drill a small hole where you think the lose bits flange is against the outer skin (for cosmetic reasons do this on the bottom of the muffler). It may have been spot wielded in place .. if you can pick those up then you have a fair indication of where to drill.

If you hit the flange - good .. if not try a different spot. Once you have it, drill the hole out to say 4 mm. Then drill 2 more holes radially around the circumference (mechanically they should be 120 degrees apart, cosmetically you want them all on the hidden side).

Now wield up the holes ensuring you get a good bond to the inner part.
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Old 05-28-2013, 03:39 PM   #13
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It's probably made by Keihan. They're in Redditch
Might be worth giving them a call.

http://www.keihan.co.uk
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Old 05-28-2013, 06:41 PM   #14
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Quote:
Originally Posted by Warin View Post
...Drop it on the end to get the lose bit jammed up.

Drill a small hole where you think the lose bits flange is against the outer skin...
That sounds good.

Alternative: earplugs and live with it.

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Old 05-28-2013, 08:20 PM   #15
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A couple of educated guess from an airhead Facebook site I'm on reckon they are Overlander mufflers, made in Australia. They had steel insides, were prone to rusting out and were considered as being not very good. I had a pair on an R100S in the late 1970s and remember them as being quite noisy.

Maybe the best thing to do is to take it to a place that repairs motorcycle mufflers and let them re-baffle both of them. If you get it done properly, you will only need to do it once.
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