1) The upper mounting bolt for the exhaust on the frame is useless. The threads on the frame actually snapped off. so there is no metal behind the bolt location on the muffler. This means that the bottom bolt has to do twice the holding of the muffler. It has caused the bottom bolt to shear off 2 times now. The first I drilled it out just fine and used another bolt. The second time I had to drill out the threads as well. Now herein lies the problem. I now have no threads in the frame so I used a lock nut and bolt combo to hold the muffler on. This recently fell off while I was riding. Is there a better way for me to support the muffler at this location? All i can think of is welding in a nut, but alas I do not have access to a welder. The bolt falling off while riding caused another problem for me too.
2) One of the studs at the exhaust flange was pulled out and broke off half-ish of the threads. Basically a little chunk of the exhaust flange broke off due to the added stress of just the studs supporting the muffler. How should I ensure the stud stays in the exhaust flange now? Sounds like another problem a weld could solve, but same problem, I do not have access to a welder.
3) Before this problem with the bolt falling off and stud coming out I noticed a slight gap between the muffler and the exhaust flange. Shouldn't this be pressed tight. The cap was probably half a quarter thickness, but enough for me to see light on either side of the exhaust gasket/protruding pipe part of the exhaust that goes into the exhaust flange. Should i just take a hammer to the exhaust and bend back the portion where its is tightened down. I suspect that it is bowed and that is why there is a gap.
I need help guys. I just got my build to keep temps below 370 and then this happens. I want to ride the d*mn thing, not just work on it!
