Repacking Steel Mufflers

[Tony T]

I'd like to keep the original muffler on a 125 Yamaha (as much for economy as original looks), has anyone either cut open or drilled a hole or two to repack an original muffler?

Or are my tight-arse ways conflicting with reality........ again.......... 

[mainline]

You should be able to carefully cut through the welds ( don't cut any deeper) and then pull the core out to repack.

[Nathan S]

See it done all the time. Apparently it's a rule that your weld has to be incredibly lumpy when you put it back together.

I've found it easier to cut away from the original weld, so your weld can be ground/sanded back.

[GMC]

Depends on how the muffler is put together.
If it is 2 pressed halves and the seams fused together then they come apart okay if you grind the head off the welds.
It can be tedious work depending on the damage.
The repair can go something like this…

http://www.geoffmorrisconcepts.com/17/muffler-repairs/