Repairing Exhaust By bodydraggers (Read 895 times)

[bodydraggers]

My exhaust on my 2010 E-TON Beamer 3 Snapped off and I need some ideas on how to fix it. I can't weld it due to it being cast metal and the holes where the bolts go snapped completely off and my engine is mounted on the swing arm so, the exhaust needs to also be mounted to it as well. Any and all ideas are appreciated.

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[Guitarman]

I can think of 3 options.

1. Drill some new holes
2. Build a partial casing around it and mount to it
3. Replace that part of the case.

That's a suck problem to have.

[bodydraggers]

I thought of drilling new holes but, on the exhaust it has tabs hanging off where the bolts go though to hold the exhaust in place and unfortunately I can drill new holes into the exhaust either. I was thinking of placing a hose clamp or any type of tightening clamp around the air filter and one around the exhaust and bolting a piece of metal between them to hold it in place. I believe the part that is broken is part of the engine and if i wanted to replace it I'd have to replace the whole engine. But, as i said in my earlier post, thank you for the help and it's helped me come closer to resolving this issue.

[oldscootcoot]

Any way to hang the muffler from the frame above? My scoots muffler is hung with bands to the frame and doesn't use the engine mounting bosses. I realize your scoot doesn't have a right side swing arm, but could you drop a mount off an existing frame member? Could be mounted to the frame with a coupla screw clamps if you don't weld.

[kz1000st]

If I'm reading the picture right the lower bolt is still there. Maybe do a super JB Weld job on an appropriate sized nut or threaded collar where the broken casting is. Then cross your fingers.

[LUKE]

I toldya, these chinese mufflers/exhaust were made from conduits and pvc pipes..very thin!...these manufacturers put the rider's safety at risk,my goodness! wake up docs, dawgs,students and rebel scooterists!!


Alley, didnt comment on my post because he knows what i said is true. ;D

[Alleyoop]

First off you do NOT want to bolt it up to the Frame You want to bolt it to the what the MOTOR is attached to. The Muffler and PIPE has to move with the MOTOR otherwise you will rip the studs that hold the pipe right off the motor.

The bolt on the bottom that KZ mentioned IS NOT one to use for that, That is to hold the PLASTIC FAN SHROUD, not big enough to take the stress of the pipe and muffler and movement.

But there is always a way, Make a U shaped bar and bolt it to the other side and bring it over to the muffler side But make sure it is attached to the part of the frame the motor is hanging off.
Then on the muffler side bolt a bar to the U bar and bolt that to part of the frame the motor is hanging off.
Alleyoop

[kz1000st]

Nov 8, 2013 14:36:24 GMT -6 LUKE said:

I toldya, these chinese mufflers/exhaust were made from conduits and pvc pipes..very thin!...these manufacturers put the rider's safety at risk,my goodness! wake up docs, dawgs,students and rebel scooterists!!
Alley, didnt comment on my post because he knows what i said is true. ;D

First off, the Eton is made in Taiwan, not China. Second, Taiwan used to be called Formosa when it was owned, ruled by Japan. The Taiwan manufacturers model themselves after the Japanese. Thirdly, he didn't come here to listen to you rant, he came for help. If you don't have anything constructive to say, DON'T!

[Alleyoop]

HAHAHAHA, we all know he is not mechanically inclined he is by all purposes just a COOK.
Alleyoop

[bodydraggers]

is there anyway you can weld cast metal? I believe it's made of cast metal and i was wondering if i could weld the bolt holes back on it.

[kz1000st]

Only if you take the cases apart to do it, then you might as well replace them. I would fear that the heat of welding would warp or damage something, but that's just me.

Only John, jct842, could answer this. How about cutting off the header pipe from the muffler and clamping on a lawn mower muffler?

[pmatulew]

Cast aluminum can be welded, but it's tricky and you're going to want a skilled professional to do it. I'd ask around your local welding shops for an estimate and then balance that against the cost of replacing the part. There are used parts available on ebay and such. You're going to have to take it apart either way.

Or you can try to fabricate some sort of substitute bracket bolted to other available mount points but there's not a lot of option and not much room to work with.

If it's a 2-stroke engine, they are really sensitive to to header length so you really can't chop it off and make a shorty.

[FrankenMech]

I can't see any of the fine grain structure in the fractures but most likely the exhaust took a hit from the side and started the cracking. It does not take long after that.

Welding is a possibility. The case is just cast aluminum. Since the engine would have to come apart it may be easier to just replace the case.

The flange does not have a lot of meat left. I can see 4 places where 6mm bolts could go (plus a fifth using the fan shroud mount) but they are not strong enough to support the exhaust system. Fabrication of new muffler mounts would be required also.

[bodydraggers]

Thanks for the help. I have some connections to professional welders in my family so, I can get it done free or at a low cost. If that doesn't work I'll just replace the part.

[jct842]

That looks like there are two places where the casting is broken. Do you mind telling us how that happened? I can see one breaking but not two.