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Muffler Repair for Honda Forman 400 ATV

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  • Muffler Repair for Honda Forman 400 ATV

    The muffler on my customers Honda Forman 400 ATV rattled. A new muffler from Honda cost $629. (However, an aftermarket version would be less expensive). I have had good luck repairing mufflers, even though you would think the high carbon from exhaust would make it difficult to weld without cracking. First, I cut off the end of the muffler using my favorite Super Slicer Plus cut off wheel on my Matabo 6” grinder. Picture 4 shows the loose pieces that were rattling around. Picture 5 shows one of the bulkheads of the muffler with a large piece missing. If you look carefully at the bulkhead beyond this one, you can see a crack in the bottom. I did not bother to repair this one because the muffler was not too loud and it would have significantly increased the scope of the job.
    1. Entire muffler
    2. Cutting off end cap
    3. End cap cut
    4. Loose pieces in muffler
    5. Broken bulkhead
    Click image for larger version

Name:	1. Entire muffler.JPG
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Name:	2. Cutting off end cap.JPG
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Name:	3. End cap cut.JPG
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Name:	4. Loose pieces in muffler.JPG
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Name:	5. Broken bulkhead.JPG
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    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

  • #2
    I bead blasted the bulkhead plate to remove the rust and carbon. I sanded the ID of the can with a Scotch Brite pad soaked in Acetone. In picture 6, you can see the new piece in place that I eventually welded to the can and the existing bulkhead (sorry I do not have a picture of this weld). Picture 7 shows me welding the next bulkhead in place. Notice the orange spot on the outside of the can of the muffler indicating good heat penetration. Picture 8 shows the washer that I welded to the bladed bulkhead. I added a washer because the outside of the bulkhead was thin but the center was solid. I wire brushed the bulkhead and cleaned it with Acetone, but in hindsight I should have bead blasted the vanes of this bulkhead to better clean it up. As you can see, the weld has some contamination in it. The weld in picture 9 that attached the washer to the ID of the can went better because it was cleaner. The last picture, #10 shows the weld to attach the end cap to the end of the muffler.
    1. New bulkhead installed
    2. Welding new bulkhead
    3. Washer Added
    4. Washer welded to muffler
    5. End cap welded back on

    -Don

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Name:	6. New bulkhead installed.JPG
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Name:	7. Welding new bulkhead.JPG
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Name:	8. Washer Added.JPG
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Name:	9. Washer welded to muffler.JPG
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Name:	10. Endcap welded back on.JPG
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ID:	592638
    Miller Thunderbolt
    Smith Oxyacetylene Torch
    Miller Dynasty 200DX
    Lincoln SP-250 MIG Welder
    Lincoln LE 31 MP
    Lincoln 210 MP
    Clausing/Coldchester 15" Lathe
    16" DuAll Saw
    15" Drill Press
    7" x 9" Swivel Head Horizontal Band Saw
    20 Ton Arbor Press
    Bridgeport

    Comment


    • #3
      Productive project and a nice pictorial!

      Comment


      • #4
        Originally posted by MAC702 View Post
        Productive project and a nice pictorial!
        Thanks, I appreciate your comment.

        -Don
        Miller Thunderbolt
        Smith Oxyacetylene Torch
        Miller Dynasty 200DX
        Lincoln SP-250 MIG Welder
        Lincoln LE 31 MP
        Lincoln 210 MP
        Clausing/Coldchester 15" Lathe
        16" DuAll Saw
        15" Drill Press
        7" x 9" Swivel Head Horizontal Band Saw
        20 Ton Arbor Press
        Bridgeport

        Comment


        • #5
          I second it, job well done. If you posted for inspiring others, you did and almost made it look too easy.
          Lol... maybe It was for you? But still a bit of work. Good on you for repairing it.

          With your tutorial of explanation and pictures, " I " thank you.
          I'm sure others as well. Some one some where is going use it to justify buying a "Mig" welder for the garage.

          From those about to weld, we salute you!

          Comment


          • #6
            Great thread. At least some people (us) will be able to view all the hidden craftsmanship in that project. Thanks for sharing... I love all your projects!!
            How did it sound??

            www.facebook.com/outbackaluminumwelding
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            Miller Dynasty 200 DX "Blue Lightning"

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