End Can Re-Packing

[Rich Oswald]

I need to re-pack the end can on my Taffy Mk4 exhaust. Never done this before so can anyone give me any links as to what to buy plus any tips ie: how to do it best and how tight to pack it etc,

Thanks,

Rich'

[coaster]

It's easier than you imagine, buy the blanket type, not the loose stuff, plenty advertised on ebay. Cut to length of the can and wind around the pipe but not tight and don't try to force it into the can. Not sure about the Taffy construction, but if its like the JL then drill out all the rivets from end near the slip joint and pull off, Remove old stuffing and wind the new one round until it is an easy fit inside the can. Use some masking tape to stop it unwinding and slip the can back on and re-rivet. If it's the type where the can is welded on then remove the end cap and hook out the old stuff and then find a piece of tubing the just slips over the perforated pipe to use as a 'former'. Cut the blanket to length of the can and wind it around your tube until it just the right diameter to fit in the can, use masking tap to hold it in place and slide the whole lot in over the perforated pipe, then pull the former out and refit the endcap.

[mr series 2]

I used these people http://www.ebay.co.uk/usr/mijexhaust?_t ... 2749.l2754
Helpfull info on there site. I used there stainless steel wire wool first then the e glasss packing

[gaz_powell]

rich - dead easy

as said buy the role

take the big circlip out and pull out the baffle assembly - unroll the old packing and cut the new same size

don't wrap it too tight - you'll get a feel for how tight by the old stuff you take out.

I use this

http://www.ebay.co.uk/itm/Exhaust-End-C ... 1633559294

gaz

[Rich Oswald]

Thank you to you all for your replies. Just one thing, my circlip is tack welded on, easy to dremmel it off but is this normal?

Rich'

[Captain Pugwash]

Thank you to you all for your replies. Just one thing, my circlip is tack welded on, easy to dremmel it off but is this normal?

Rich'

Hi Rich,
If you've got the end can off then while it's apart take a look at the tail pipe that's the piece that's connected to the main body of the exhaust between the body and muffler

If you stick a screw driver down the inside and scrape at the inner wall of the pipe you will see how much carbon has collected, if it's heavy and reducing the diameter then while it's apart you could de-coke it a little.

If it is badly coked up, removing any carbon build up should help the scooter run a little better and a bit cooler, mine both Taffspeed pipes were very heavily coked up after a couple of years riding.

Mark.

[Rich Oswald]

Cheers Mark , it's not off yet but will be tomorrow. I will have a good check, thank you very much

Rich'

[Wack]

The circlip is welded to the end cap to stop it pinging out which is what happens to that type of end can, remember Frescos? As you squeeze the clip together , pull n twist the tail stub out.

[Digger]

The circlip is welded to the end cap to stop it pinging out which is what happens to that type of end can, remember Frescos? As you squeeze the clip together , pull n twist the tail stub out.

Thanks - I was scratching my head over mine.

[Captain Pugwash]

The circlip is welded to the end cap to stop it pinging out which is what happens to that type of end can, remember Frescos? As you squeeze the clip together , pull n twist the tail stub out.

Thanks - I was scratching my head over mine.

I've had to grind off the weld between the end cap and circlip. They do normally come off with circlip pliers.

But if it doesn't and you have to grind the weld off, then if you need a replacement circlip I have one spare.

Mark.

[Rich Oswald]

Thanks Mark that's great to know if I need it.

Rich'

[Rich Oswald]

rich - dead easy

as said buy the role

take the big circlip out and pull out the baffle assembly - unroll the old packing and cut the new same size

don't wrap it too tight - you'll get a feel for how tight by the old stuff you take out.

I use this

http://www.ebay.co.uk/itm/Exhaust-End-C ... 1633559294

gaz

Thanks Gaz, i've ordered some of that stuff. Not gonna take the circlip off until it comes as I'm off to Scarboro' this weekend so it will probably be Monday now.

Rich'

[Dazts1]

Hi Rich , I must have packed 5 or 6 Taff endcans. I've never had to grind the weld in the circlip. Just use your circlip pliers and it all comes out in one piece. Circlip will still be attached to the centre of the endcan. I'll post a couple of pics in a couple of days to show you. Couple of late shifts at work the start of this week.

[rossclark]

It its a bit sticky use a spring hook and hook it into one of the holes in the tube in addition to the pliers.

[Captain Pugwash]

It its a bit sticky use a spring hook and hook it into one of the holes in the tube in addition to the pliers.

That's what I've usually done using my exhaust spring puller and sometimes a screwdriver just to shimmy the circlip and the end cap out of the circlip groove.
The one I had to grind off had been welded in a position that left little or no movement even if the circlip was fully compressed.
it depends how tight a fit the disc is in the end can, and where the tack welded circlip sits on the endcap for how easy it comes away.

But they do usually come away with not too much effort.

[Rich Oswald]

Well Mark and Daz,i've had the circlip free of the groove, been pulling with the spring puller, had screwdriver behind it but can I hellers like get the twat out. What's stopping it?

Rich'

[Captain Pugwash]

Well Mark and Daz,i've had the circlip free of the groove, been pulling with the spring puller, had screwdriver behind it but can I hellers like get the twat out. What's stopping it?

Rich'

I had that with the one I ground the weld off the circlip spent ages twisting pulling but no matter what I did I couldn't get it out.
I resorted to the dremel with a mini cutting disc took a few mins but the circlip once free of the end cap came away then I just wiggled and pulled at the tail pipe and it pulled free.
I bought a few new circlips incase I ever needed to repeat the same on another.

So if you do have to butcher yours I will send you a replacement.

[Dazts1]

Have you removed the endcan from the scoot or pipe rich ? I have found the best way is to leave the pipe/ endcan fixed In place then you can put your efforts into the removal of the center of your can. Without struggling trying to hold it in place. With the pliers and a small screwdriver being careful not to bend the ally muffler. I've always found a little bit of side movement on mine. Does the center twist slightly inside the ally muffler ? Mine does. Once you've released the circlip just ease your screwdriver in and pull at the centre pipe. Admittedly 3 hands would be better than 2 but it should come away. With the pipe fixed to the scoot you pulling the center out against the weight of the scooter it should come !

Good luck !

[Rich Oswald]

Yes Daz, the can is still on the pipe. Believe me I have tried all those things and it just will not budge. The weld is only to the end plate so it's not that holding it.
Gonna leave it till Monday now as I want to go to Scarboro on it tomorrow to give the cyclone its first proper run.

Rich'

[Rich Oswald]

Well guys i've done it but what a job! Dremmeled the weld off and took the circlip off, still wouldnt budge. Had the wife as a 3rd hand, no luck. Took the whole end can off the exhaust, turned it upside down in an open vice and had to use a drift to knock it out from the other end and even that took some doing. Re-assembling was just as tight. Had to chamfer the leading edges of the mesh tube and the inside of the can just to get it started and then rubber mallet it back in. The circlip mostly survived Mark so won't be needing one thanks but it aint gonna come off even without one, lol.

Thanks a lot for all your replies and help,

Rich'