Repair cracked stainless exhaust

[Kram]

Ive been ignoring my exhaust about a year and now a small hole has spread into a crack. Id like some advice, the best way to weld it up, before it falls off The hole was caused by me falling off on ice, it bent the exhaust and ripped an internal weld. Also becuase its slighty bent, refitting was not easy.

Will stainless care that crack has been exposed to exhaust gasses? I'm aware carbon makes stainless brittle, should I grind the damage out and patch it with sheet?

I can get a better pic tomorrow. This is the other side, when it was much cleaner.. The hole is on the left side of the bike, next to the mounting bracket (left of pic). Crack spreads round the diameter parallel with the weld (right of the bracket)

 

[pedrobedro]

I welded one on a Hornet with ordinary mild wire for someone who just wanted it quietened down to get rid. I just welded over the crack to stop the blow and two years later it was still running round quietly. I don't know where it is now though it has gone out of the area.

 

[Kram]

Ive got stainless wire and argon, not ideal, but should do the job. Very tempted to remove battery, ecu and weld it in place, probably less effort than refitting a bent, distorted exhaust.

 

[Chris Stevens]

Lots of stainless car exhausts are welded using mild steel wire. Its cheaper and less likely to crack, and will work fine on your pipe.

 

[Richard.]

Lots of stainless car exhausts are welded using mild steel wire. Its cheaper and less likely to crack, and will work fine on your pipe.

Depends on if the op is ok with it going rusty which is what a mild steel joint will do in no time. I'd tig it with a drop of 308 personally. Would be easy enough left in place.

 

[AndyStobbs]

Get a mini spool of 308 mig wire? I would do it fitted. Much less work, clean up a spot for earth clamp on the exhaust.
However you do it you might still end up with carbon in weld pool from the inside.

 

[sapperb]

When cleaning/prepping the area, stay away form high speed grinders.. elbow grease with dedication or maybe pnuematic grinders with mild grit to clean the welding area. High speed grinders with heat up too much and you are already dealing with thin metal which will possibly cause you to burn through. Pnuematic grinders or by hand will allow you just the right pressure to prep the area and salvage what thin metal you have to work with. also goes for where you are going to clamp the earth ground, like AndyStobbs said.

 

[Jim_gsxr1000]

Just weld it with scratch start or lift tig, no need to remove the ecu !

 

[Chris Stevens]

I would have thought the chances of broken studs when removing and refitting the exhaust to Tig weld it, are far more of an issue than bit of corrosion on an in situ Mig welded repair?

 

[Richard.]

Why does it need to be removed to tig weld it Chris. I said in my post I'd tig it on the bike.
No way would I strip it down when the crack is that accessible.

 

[Kram]

This is going to wait a couple of weeks, not great as days are getting shorter! It will be mig as that is all I have Crack is between the sump and the bracket, not that accessible. It has been removed this year so studs are all free and covered in copper paste.

 

[Richard.]

Sounds like it's all in hand. Good luck.