Repacking aftermarket exhaust can

Y

Yama4stroke

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New Hudson
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USA
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2015 Yamaha viper STX-DX
Has anyone repacked an aftermarket exhaust can before? I've done it a couple times on dirt bikes and Harleys but those were pretty easy to just drill out some rivets or unbolt the exhaust tip and repack.

I have a BMP Full Velocity can on my Viper. I've had it on my Viper for 4 years and about 7000mi. It started getting really loud last year and I could not find any leaks anywhere. Contacted BMP about a repack kit or having it repacked and was told my only option was to purchase a new can. I liked the exhaust sound and sound level until last season. The performance and weight savings were great so I don't want to go back to stock but also don't wanna shell out for another new can at $399.

Has anyone had any success repacking aftermarket sled cans? There's no unbolting or drilling out rivets on this one. I'm looking at 2 options.

Option 1 is I will cut a couple windows into the can to pull out the old packing and fill it with new. Thinking I will cut one hole into the top of the can to the right of the inlet and another on the bottom to the left of the outlet.

Options 2 is to grind the welds to pull the can apart and repack it, then reassemble and weld it. My concern with grinding the welds and pulling the can apart is that the mounting points and such may not line up after reassembling and rewelding everything unless its exactly perfect like it was from the factory.

Any input is appreciated. Thanks

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My guess is there is no packing inside that can, just a bunch of screen and baffles, thats why you cant open it up.
 
It's a flow through muffler. In the email I got back from BMP they said to repack it that it would have to be torn apart then rewelded and that it wasn't worth it on their end which makes sense to me. They're not going to cut a window in to repack it because it would look tacky but it's under the hood and as long as it functions properly I'm ok with it. I will definitely post pictures if/when I tackle this project.
 
Yama4stroke said:
It's a flow through muffler. In the email I got back from BMP they said to repack it that it would have to be torn apart then rewelded and that it wasn't worth it on their end which makes sense to me. They're not going to cut a window in to repack it because it would look tacky but it's under the hood and as long as it functions properly I'm ok with it. I will definitely post pictures if/when I tackle this project.
Click to expand...

Gotcha ya. If your a good welder it would be pretty easy. I would do it for you if you live near by.
 
I will take a pic of one that I have run that won’t burn out and has very little effect on power. Yoshimura.
 
I don't know about that one you have but I repacked my hindle last year. Just had to drill out the rivets and pull the inside of the muffler out. I got the packing from hindle. It was a little tricky getting it all in their but do-able. If you can get get it apart you could always just drill holes and put stainless rivets in if you didnt want to re-weld it.
 
As I look at it though I agree with Mr Sled, usually when the inlet and exhaust are offset like that it's just wire and baffles inside not packing. The reason the sound has changed is that those baffles are rusting out and breaking down internally.
 
I got the can cut open with an angle grinder and a cutoff wheel. It's definitely a packed muffler. The factory packing was pretty wasted. There wasn't much left of it.

upload_2021-1-11_11-23-59.png


It looks like there was probably some steel wool packing in the can originally with fiberglass packing but its pretty much blown out. All this debris must have been what I heard rattling around when I shook the can.

upload_2021-1-11_11-24-52.png


I removed all the factory packing and inspected the flow through tube for any issues. It's in great shape.

upload_2021-1-11_11-26-3.png


I ended up repacking with a kit from International Steel Wool Corporation. They are located in Roseville, MI just outside of Detroit. The Muff Pack kit I ordered came with a stainless steel wool mat that gets wrapped around the flow through tube, a stainless mesh that gets wrapped around the steel wool, stainless mechanics wire that gets tied around the mesh and the wool to hold it tight and ceramic mat packing the wrap around the wool and mesh as well as to fill the rest of the can. This is the link for the kit I ordered. It was $44 with free shipping. https://shop.steelwooldirect.com/product/muff-pack-carbon-fiber-muffler-repacking-kit/
It comes with ceramic packing mat instead of fiberglass. It's rated to 2600F instead of 1150F for fiberglass and is supposed to last longer. Their website claims wrapping the flow through tube with stainless wool and stainless mesh, then packing with ceramic or fiberglass will make the packing last 4 to 5 times longer than packing with fiberglass alone. We'll see on that I guess. I probably won't own the sled long enough to find out.

upload_2021-1-11_11-30-20.png


I forgot to take a picture of the stainless steel wool and the wire mesh when it was wrapped around the flow through tube but in the above picture you can see it a little. I wasn't sure how tightly to pack the can. I packed it what I would call in the middle. I definitely could have packed it looser but I also could have packed it a little tighter as well. I used all the steel wool and stainless mesh and about half of the 1/2" X 24" X 60" ceramic mat.

upload_2021-1-11_11-30-38.png


My brother Tig welding the can back together. He's a much better welder than me.

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The finished can.

upload_2021-1-11_11-36-34.png
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I'd say the only downside is that the welds and the metal next to the welds no longer have the ceramic coating but it's hidden under the side panel and nobody will see it. The can was no good to me being blown out so I'll take a little rusting around the welds to have the sound back to a manageable level. It took about an hour and a half to take the can out, cut it open and pull everything out, repack it and weld it shut. Well worth the labor and $44 packing kit compared to spending $400 on a new one.
 
Nice job!
Ill send you my Turbo force TD muffler that has 10K on it? LOL .. Same thing I'm guessing . Man its gotten loud. I ordered a new one as I have no welding ability or time to deal with it.. Maybe someone will buy it for 100 bucks and do what you did.
 
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