Strategy for attacking the muffler

[Dragon]

My Hibird 250 muffler is loud. The sound is very harsh at higher RPM, but strangely enough, it is pretty quiet at low RPM. I suspect the baffle inside is loose or broken. I don't know how to weld, but I'm going to cut the muffler open anyway and hope I can rivet sheet metal over the opening. The question is: where should I make the cut on the muffler?

[culcune]

Keep it loud!! 8O

[Dragon]

And lose my hearing?

[knothead]

Wear ear plugs. I do and my bike is quiet, but the noise of the wind is enough to slowly damage your hearing by itself.

Riveting the muffler won't work out too well. It will leak and eventually sound even worse than it does now. You might be able to have it rewelded at a muffler shop. Another option might be to look around for a tractor muffler or a glasspack, I've seen them used on bikes before, but have not heard any in real life.

[katoranger]

I second the earplugs. I use some and just put them in lightly so that I can still hear things around me.

My exhaust is louder than stock.

Allen

[katoranger]

One more thing. I remember someone removing the cone shaped piece on the end of the hibird 250 muffler. Doing this helped reduce the sound.

Allen

[Cal25]

That was the Dragon himself.

[Dragon]

Yep, that was me. I've put 7000 miles on the bike. It sounds a lot harsher now then it did brand new. I leave the bike outside during the day, both rain and shine. I see alot rust spots on the frame and muffler already. So, I think something inside the muffler must have broke. Also, I ride much faster now then back then. I go on the freeway everyday and do nonstop 60-70% throttle for 10 minutes. The bike is screaming at that speed and RPM. It needs more muffle.

[katoranger]

My stock muffler lost the baffle. The honda part sounds much better. No raspy rattle. Deep and loud. The only downside is the loud. I can make the exit smaller, but it also noticably hurts performance. I think my best solution is to create a turn down of some kind to help point the sound away from me.

Allen

[AZ200cc]

Yup quieter means lower performance.

[Dragon]

I see Arc Welder on Harborfreight for less than 100 bux. Is it easy to use? Do I need to take a class for it?

[katoranger]

Usually an arc welder is going to be hard to use on light metal. You are going to want a wirefeed type and also be able to control the amps to a low level so you don't burn holes in the exhaust.

Welding light metal is difficult if you are not experienced. You don't need to take a class though. I have a hobart handler 140.($400) I can weld most of what I want to do with it. It is also setup of to use gas for a flux and not just flux core wire.

Buying a welder is just like a china bike. Make sure you can find parts. I can buy most supplys are the local TSC or Home Depot.


My Dad uses an Oxy Acetolene torch and coat hanger to weld light metal together.

Arc is usually better suited to metal 1/8 thich and heavier.

Not I know some here are pro welders and will have better knowledge to share.

I just usually make it stick together. (Also known as slobberin here)

Allen

[DDG1976]

Kato's right, there's not much on these bikes that can be done with a stick welder. Granted you can turn it down and use 3/32 rods, but that would be something I wouldn't want to do and I've been a welder for 16 years. Harbor freight was running a sale a couple weeks ago and had a wire fed 110 volt welder for $149, that would have been perfect, it came with flux core wire so that you could weld without having to get a bottle and a regulator. I don't know if they are still on sale, but it might be worth looking into, if you plan on welding more than just a muffler once.

[katoranger]

Here is a cheap one. http://www.harborfreight.com/cpi/cta...emnumber=94056

There is a cheaper one yet, but this one has 2 amp settings. You would want that.

Spend another $20 and get this one if you have a TSC nearby. This will weld most anything the average homeowner will work on. Easy to use after alittle practice.

http://www.tractorsupply.com/webapp/wcs/stores/servlet/ProductDisplay_10551_10001_49007_-1______14151|14220|14238|49007?listingPage=true&Sp ecial=false

[elroyjetsn]

I took out the little tailpipe and it was only tack welded to the little baffle.

Then, i enlarged the opening to accept a short length of aluminum pipe with holes drilled in it.

Now it has a real baffle giving it a nice Honda-like sound and at the same time is less restrictive than stock pipe.