How can I fix my muffler end cap?

[Mozenrath]

I took a ride this morning, and after all that time I couldn't get it off, the end cap fell off on its own. I went back to get it, but right as I got about 100 feet away a street sweeper came and ran over it. Didn't suck it up but now it's all bent out of shape.

If I can get a piece of steel, drill out the right size hole and have it welded on, would that be a good solution? Would it have to be rounded out or would flat be just fine? Hopefully I can find a big washer that will work.

 

[Texhun]

Most people find a can the same size and just chop it to size and screw it on, dosn't look as good but hey, it works. What you can also do is cut a flat piece of metal and just weld it on. Or the washer idea would work great too, just make sure the opening isn't too big.

 

[Mozenrath]

I've heard about the can thing, but I don't see how thin aluminum would stand up to the muffler heat. I also couldn't weld it on, and I kinda want to finalize the muffler. In other words, I want to end the worry of it or parts of it falling off when riding. I just want to freaking ride already!

I will probably just go with a piece of steel or a big washer. I just wanted to make sure there wasn't anything about the stock end cap that was important to engine performance.

 

[Texhun]

You might notice a change in power but not much and it might be a tad louder but still to where it won't bother anyone.

 

[andrewflores17]

i did the washer welded on on my old two stroke still on that muffler holding strong

 

[California]

http://motorbicycling.com/showthread.php?t=37217&highlight=MUffler+end+cap+fix