repairing exhaust, jetting, etc

[roost]

I'm now working on the exhaust for a 80' gs 750. Currently, the exhaust is badly rusted. I have stock air box and prefer to not spend much money.

I see my options are:

1. take off the exhaust, try to patch all the holes, put them back on....
2. buy an aftermarket 4-2 mac exhaust, rejet
3. leave the headers, cut the rusty exhaust, weld an aftermarket exhaust (such as a 12" emgo)


My questions are:

1. how do you repair a rusted out exhaust?
2. If i buy an aftermarket exhaust, how do i determine re-jetting main and pilot? Is there a link with this information?

Thanks

[Steve]

Depending on where and how bad your exhaust is rusted, I might be able to help answer one of your questions:

1. how do you repair a rusted out exhaust?

Mine was rusted out behind the passenger footpegs, in the middle of all the baffles. I knocked on the pipes to find all the loose stuff, reached in and got out what I could. Then I put a bead of muffler putty around the hole and around the edge of a piece of aluminum, then riveted it in place.


I have not yet had a chance to clean it up as well as I would like, then polish it, but it doesn't look too bad, especially since it's under the saddlebags.



Yeah, it's another one of my "motel parking lot projects".

While here, I have installed a CB radio/intercom/music player, adjusted my valves, synched my carbs, patched my mufflers and replaced the tires.
OK, I had to go to a co-worker's place to do the tires, but everything else has happened right out in front of my hotel room.

.

[Dibber]

I used JB Weld puddy stick to patch small holes in my pipes, but know I'm experiencing a lot of rattling that is getting worse in time, from the header pipes. An 20 yr plus Suzuki Mechanic told me that my 81 GS450T headers are doubled walled and the inner walls rust out causing the rattle. Darn...he told me not to buy used pipes because they could rust out at any time too. Darn again...NOW I might be looking at MAC 2 into 1.