Exhaust repair questions

[Petorius]

After badly mangling my exhaust can during the Classic, I decided to attempt a repair and hacked it to pieces. I have a few questions about the finished product. Pics to come later.

1. The end-cap piece on the mid-pipe end of the can assembly was bent such that the inlet tube of the can assembly (which connects to the mid pipe) enters the can assembly at about a 45 degree angle. I banged away at this thing for over an hour with all sorts of tools, heat, a pry bar, etc, and could not get this to budge even a little. Just dented up the end-cap more. Will the sharp 45 degree bend entering the exhaust can cause problems or rob power?

2. Due to dents and other damage to the side wall portion of the exhaust, the end caps did not fit back into my shortened can perfectly. Especially on the mid-pipe side, there is definitely some space between the end-cap and the side wall piece, even after riveting. From the factory, there was some kind of silicone sealant looking stuff in this area. I did not apply new silicone, although it is not too late to go back as I want to use shorter rivets anyway. Will an open gap here cause problems? I know exhaust leaks are supposed to be bad and all, but I dont really understand why, and this is pretty far back in the stream (in the can).

3. I took all the packing out in order to inspect the baffle. Should I put it back in? The thing is definitely too loud now (although very amusing to rev), but is there a performance reason to replace the packing? I will just stuff the old packing back in, if so. It is probably just going to be used as a spare now, anyway.

Edit: Pictures added. First one shows un-fixable bend, second one shows gap around front end cap, third one shows what it will look like when done.

[jasnmar]

1. I don't yet understand the problem.
2. Use this Amazon.com: Permatex 80335 Muffler and Tailpipe Sealer, 3 oz.: Automotive
3. Packing difference doesn't make any significant impact on performance, but it does you garage mates hearing .

[Petorius]

Pictures added. I guess the angle of the inlet tube is not as bad as I thought. I can still see through it end-to-end, not much obstruction. I can rotate it around on the midpipe so that it points straight back and not towards the rear wheel for a cool "custom" look.

Assuming that one end-end cap is going to fit better into the side-wall piece than the other, would it make more sense to have the gap (shown in picture 2, currently on the mid-pipe side) on the leading end or back end of the can assembly?

[nhbubba]

I missed this thread the first time around.

That muffler is short!

I think that you want to seal the caps. An exhaust leak will cause performance problems, including popping. At least it did for me. My exploration of T1 last round left a hole in the side of my pipe. I just took mine apart to try to fix it. Wound up cutting the pipe down about 2".

The packing was almost entirely gone. No wonder the damned thing sounded so loud great.

Now, does anyone know of a good source of exhaust packing with quick turnaround? As usual, I've left this to the last minute.

[jasnmar]

Bearing in mind I have no clue about this... Amazon.com: FMF Racing Muffler Packing for 4-Strokes 010590: Automotive

I've heard good things about the fmf 4c packing. It's on amazon... I knows you amazon.

Yeah. Pete... It's so short...

[isaac_]

Yeah. Pete... It's so short...

That's what she said.

[carsick]

But it's wide, and he knows how to use it. Plus he's on an SV, so there's no rush.