Author Topic: Gen 1 - Exhaust end can support bracket repair  (Read 927 times)

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Offline Robin

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Gen 1 - Exhaust end can support bracket repair
on: October 25, 2020, 08:00:59 PM
Whilst touring Scotland in September the bracket holding up the original end can on my 2011 Explorer broke.  It always looked like a weak point and on this bike I’ve resisted changing the end can for a lighter alternative.

I did consider just welding the bit of tube back on to the hanger on the frame but the amount of metal that holds the tube is tiny. I doubted that even a good weld would have lasted very long.

The bracket on the frame is strong enough so I set about thinking how to attach something to the bracket that I could securely weld the existing support tube to. A scrap bit of 10mm steel plate was found and with the help of a cardboard template the steel was cut and shaped to fit behind the bracket. The bottom of the plate which would hold the tube was shaped to hold the tube at the correct angle.

I had to make a jig to hold the plate and tube in exactly the right position for welding up. Once cleaned up I needed to fix it in place. Because of the triangular shape it sat tightly inside the existing bracket and would only need to retained by a fixing bolt. I bought some large stainless steel repair washers and 8mm washered bolts. I cut one of the repair washers to the same shape as the bracket  so it would look the part.

I assembled it all including the end can so I could be sure it all fitted together and then stripped it down for painting.
















Last Edit: October 25, 2020, 08:03:07 PM by Robin
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#1

Offline Will Morgan

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Re: Gen 1 - Exhaust end can support bracket repair
Reply #1 on: October 25, 2020, 10:35:49 PM
Nice work!

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Online glenn389

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Re: Gen 1 - Exhaust end can support bracket repair
Reply #2 on: October 25, 2020, 10:48:32 PM
Cracking job. 👍

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Offline Rigsville

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Re: Gen 1 - Exhaust end can support bracket repair
Reply #3 on: October 26, 2020, 09:55:52 AM
Excellent job, have you considered making a small batch and selling them?

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Online Jon

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Re: Gen 1 - Exhaust end can support bracket repair
Reply #4 on: October 27, 2020, 02:08:20 PM
That looks great! :028:
Jon

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Offline Robin

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Re: Gen 1 - Exhaust end can support bracket repair
Reply #5 on: October 28, 2020, 12:36:25 PM
*Originally Posted by Rigsville [+]
Excellent job, have you considered making a small batch and selling them?

Yes I considered it but is there a demand? I think most owners upgrade to a lighter end can and I suspect that avoids overstressing the miniscule welds that hold the tube onto the support.
It was also quite time consuming making a one off. 
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Online Ollyreid

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Re: Gen 1 - Exhaust end can support bracket repair
Reply #6 on: October 28, 2020, 01:19:31 PM
*Originally Posted by Robin [+]
Yes I considered it but is there a demand? I think most owners upgrade to a lighter end can and I suspect that avoids overstressing the miniscule welds that hold the tube onto the support.
It was also quite time consuming making a one off.


Hi Robin,

I think this is a great idea and looks so neat!!

Definitely a demand from me!  I'm sure mine's on the way out as there's a bit of rust developing there and despite my cleaning / painting efforts I'm not happy with the look of it. 

A fix like this (preventive medicine) would definitely be peace of mind!!

I actually carry a large s/steel jubilee clip as a roadside fix in case it does go. 

Olly