Previous owner welded leaky exhaust

[KameHouse]

I started my project today of my newly acquired K4. Did a compression test warm (170 left and 175 right). I noticed the air coming from the right muffler was weaker than the left, then I discovered a very poorly done weld job connecting the right pipe to the muffler. I put my hand at the joint and found steady light puffs of air coming from the bottom side of the joint.

The mufflers are both in good shape so I don't want to replace them if I don't have to. My plan was to break this weld, grind it off and start over. Any suggestions greatly appreciated!

 

[LongDistanceRider]

That's really about the only thing you can do, grind it away and get a good clean weld in place.

 

[fxray]

It's hard to tell from the pictures, but it doesn't look like the header pipe is welded to the muffler inlet. It looks more like the muffler inlet is welded (sort of) to the rest of the muffler. The header pipe fits inside the muffler inlet. In any case, that right side muffler is toast. It is crushed so badly that it may be restricting flow. I'd be looking for one to replace it, rather than worry about the weld.

 

[Juneaudave]

We need a pic of this weld job in the "PO Hall of Fame" thread! https://www.vintagehondatwins.com/forums/showthread.php?7993-PO-quot-Hall-of-Shame-quot-Photos