This exhaust system was taken from our own Suzuki T 250 Hustler restoration and as with all these 40 year old classics they have a story to tell. In this particular case it had some nasty creases and dents, but the condition of the original stamping was good.
We chose to split the exhaust into two pieces to give us access to the dents and in the process re welded the baffles.
With minor dents and scraps we can tig braze and make successful repairs at reasonable cost.
The Exhaust Repair Process
The first stage with these silencers is to clean them out to remove all the old carbon deposits and then to Chrome and Nickel strip them. We then take a very light polish to the surface of the silencer to highlight any dents and scratches. As you can see from the picture our silencer has some very nasty dents.
These dents were just to deep to fill with our conventional tig braze. So the only way forward was to split open the silencer and dress them out from behind. This was quite a useful method because in the process we found a loose and corroded baffle which we were able to repair at the same time.
Once all the dents were removed we pre polished the parts before seam welding the two sections back together again. After welding the silencer is polished again ready for Chrome plating.
The finished polished Chrome silencer preserves all its original stamping "T 250 Do Not Modify This Silencer".