Ok so I was out today and crossed a swamp which Ive gone through a 100 times before and when i got out of the water and nailed the throttle it sounded like hell and wasn't feeling right, so I stopped and pulled the plastics off the side and noticed that the exhaust pipe was cracked all the way around the pipe was in 2 sections. Anyone out there have luck welding this stuff back together? I really dont wish to pay $100 for a new pipe.

Thanks

 

Well, all the fix jobs i've heard of work for a while, but then they crack again, so take that for what it is

What bike do you have?

 

04 Sportsman 600 twin

 

So no one out there has ever welded a cracked exhaust before?

 

(Welding 101) Depends on where the break is. Welding on thin wall exuast pipe is a little tricky for the inexperianced but can be done. You have to be careful not to overheat the pipe or burn threw. My suggestion is to find a piece of pipe slightly larger about 1-2 inches long that will just slip over the existing pipe . Slip it on before you tack the break. Once tacked slide the new section over the break 50/50 if possible. Then tack all the way around at both ends. This method will be stronger than just welding the crack. So the answer to your question is yes, but if your unsure about doing it yourself then don't! Take it to skilled welder. A weld that has been burned in correctly will actually be stronger than the steel around it, but incorrectly will weaken the steel and most likley break again. Also you might be able to find a muffler shop that could fab up a whole new pipe or do the welding for you.

 

Buy a new pipe for an 800.

 

ok so the pipe is welded back together and seems to be holding fine so far. And yes if it cracks again Ill be buying a 800 head pipe!