| Author | Message | ||
     Hangetsu |
I’ve read about the notorious “Rusty Muffler on many Bad Webber profiles under the “Problems” heading. The word seems to be that some mufflers have been known to rust prematurely, but I did realize how prematurely and to what extent. I am wise to the situation now. I purchased my 09 Uly at the end of October, so about six months (crap, has it been that long?) ago. I’ve ridden all winter, but except for one trip, I have never ridden when the roads were wet. At the beginning of this month, I did take a trip to New Mexico and on the final stretch coming home, I did encounter some snowfall and slushy/gritty roads. This was the only time the bike has seen water other than an occasional puddle in the road. Never-the-less, seemingly almost instantly, the muffler has exploded in rust from the collector to the butt end. The paint is literally jumping off and everywhere the steel is exposed, it’s covered in red powder. Now here’s my conundrum: I’m not really upset over the matter, though I find it kind of odd that a company like Buell would not put a little more R&D time in choosing the coatings for a part that is SO exposed to the road and elements. The bike is dealer honored the warranty with no hesitation and has already ordered a replacement part. What I would like to know from you kind folks is, have they done anything to resolve this issue, or will I likely be facing the same situation with the replacement a few months down the road? I am considering having the new muffler sent directly to Jet Hot for a ceramic coating before they install it and I’m wondering if that will be money well spent. Any thoughts from those who have experienced this problem would be greatly appreciated. Thanks A- | ||
| Johnnylunchbox |
If I open a bar it'll be called "The Rusty Muffler" | ||
| Hangetsu |
Just don't serve Bud Light and I'll be your first customer. | ||
| Rkc00 |
I am on my third muffler in 3 1/2 years. The last one I put on I had ceramic coated. Hope it works to keep the rust off.   Mike Long Island, NY 06 XB12X Red/Black | ||
| Tginnh |
I just got my muffler back on the bike yesterday. I had pulled it to repaint due to rust and discoloration. I wanted to jet-coat mine, but personal finances dictated otherwise. I went the $5 dollar can of dupli-color, hi-heat, semi-gloss instead. I would jet coat my pipes and muffler if I had the dosh. | ||
| Joesbuell |
Wow! I'm glad they don't need to salt the roads here in Oz  | ||
| Jlnance |
Long Island, NY Love them salty roads. | ||
| Crusty |
Wasn't The Rusty Muffler a bar in the movie Cars? I had the exhaust on my '06 Uly Jet-Hot coated black. It was fine 15,000 miles later when I traded it in on my XT. So far, I'm letting the muffler on my XT rust. | ||
| Bienhoabob |
I'm with Crusty. Just letting mine rust. Maybe if we all show up at homecoming with rusty mufflers, Buell will do something about the problem. | ||
| Electraglider_1997 |
<i'm> Yes, they'll sell all of you a new one. Hey, it's the only way they've got to make up the lost warranty costs on the rusty cans they've had to replace. There is such a thing as Stainless Steel. Stainless means happy customers, less warranty issues for Buell. Seems like a no-brainer to me. Bean counters can ruin a good company. | ||
| Hangetsu |
Doesn't have to be Stainless. All they have to do is ceramic coat them as part of production. With those economies of scale, I'm sure it wouldn't be an expensive thing to do, especially when considering how many they have to replace. On an $11,000 M/C I would expect a little more attention to be spent on such very basic quality issues. | ||
| Electraglider_1997 |
Ceramic or SS. SS can get dented without chipping and wouldn't get any hotter than what is currently used. Ceramic chips (?), retains heat and emissions go up (?). I'm just guessing on the ceramics. Anybody know? | ||
| Ejc |
I had my muffler ceramic coated last fall. It had rust on it prior. The rust is returning. I did the pipes too. They look good. | ||
| Hangetsu |
Once iron begins to rust, unless all oxidation is removed from the metal before coating, even that which you can't see, it will come back and eventually bleed through any material. Rust is like cancer, unless you remove it ALL, or coat the material before oxidation begins, it will come back. | ||
| Hangetsu |
Looking at the photos above, I have to laugh. Don't get me wrong, I love my Buell and I will likely buy another one at some point in the future, but despite how well it may function, that muffler is built with about the same quality of materials, fit & finish of a stove pipe. | ||
| Ejc |
Hangetsu, I understand oxidation. I knew I was taking a chance that all the rust may not be removed. I guess the take home message is ceramic coat when you get a new muffler for best results,(if you want stock). | ||
| Natexlh1000 |
I like that it's mild steel! They don't sell race cans anymore so you can still make your own with a hacksaw and a stickwelder  Stop crying and go buy a can of krylon barbecue paint!  | ||
| Werewulf |
Rust never sleeps! | ||
| Ourdee |
I'm bringing mine to HC.  | ||
| Royintulsa |
It's the engineers way of telling you to get an aftermarket pipe so it will run the way it was designed rather than the way the E.P.A. and C.A.R.B. would like for it to run. | ||
| Chrisrogers3 |
One would think that Buell would look into some corrosion prevention measures. The corrosion isnt necessarily due to salt at all on many Buells. Its due to an increased flow of electrons between dissimilar metals, there are what 2 different types of metals touching the muffler-thats a HUGE no no when it comes to corrosion prevention. Especially when there is steel and aluminum involved. If you dont believe it study reduction/oxidation reactions sometime or galvanic cells. If you guys want something to stop the corrosion or at least slow it down, look into buying some Ultra Tef-Gel. This is what the USMC requires its vehicles use as part of their "22 year corrosion control program" The stuff works (but has to be reapplied every so often). | ||
| Hooper |
I was with Chrisrogers3 until his second sentence. Unless I'm clueless (which is highly possible), this is a design flaw of the highest degree. The fact that it is happening year after year lead me to believe (as a project manager) that Buell does not believe that its users care that much. The product RUSTS, yet it WORKS. For me, that's enough. If my '06 rusty muffler keeps "muffling" (frankly, I wouldn't mind if it sounded a little nastier, but I prefer to keep the air slightly cleaner), I'm not going to replace it. Same as with my car. However, if my car starts sounding like one of those wanker Honda Civic 4-door 4-bangers with a trumpet on the tail end, I'm going to raise Hell. That hasn't happened yet. I do find it highly strange that the mufflers rust for 3 years in a row. That's not right. Yet, I love Buell enough to barely notice it. | ||
| Tginnh |
I was able to follow Chrisrogers3 post because I had galvanic corrosion explained to me once by a tech services guy that works for an industrial coatings company. So, I just had mine off the bike for a repaint and the only dissimilar metals that I can come up with are steel and stainless steel. How does the stainless exhaust pipe account for rust all over the muffler? Does galvanic corrosion work that way? btw - Chrisrogers3, your definition is book precise. | ||
| Nobuell |
Galvanic corrosion will occur at the coupling point for this type of application. Actually carbon steel and Stainless steel are not far apart on the galvanic series table. Over all rusting is not a galvanic issue. Carbon steel and stainless steels are commonly used together in industrial applications. Painted carbon steel will just eventually rust when exposed to water and salt. The only way to eliminate it is to use a corrosion resistant material. | ||
| Petereid |
I think its simply road crap damaging the finish and then the heating and cooling cycles accelerating the oxidation. Perhaps a high heat stone and chip guard coating would help under the paint (if they make such a thing) | ||
| Chrisrogers3 |
The rear muffler brackets I thought were aluminum (you know those brackets that those huge hose clamps go around). As far as rusting all over, my guesses are (that rear bracket is indeed aluminum) the flow of electrons goes all the way back. The other thing could be is that the heat could act as a catalyst. All I know is as soon as I can get one replaced under warranty I am going to throw tef-gel on all the contact points and monitor it. I was able to find this website. http://www.tefgel.com/contain.php?param=tefgel_inf or | ||
| Tginnh |
That's right! The muffler comes in contact with a HUGE hunk of non-ferrous metal. Good point. My muffler was no where near as rusted as some of the photos that have been posted. I'm too freakin anal to let mine corrode. I cleaned mine up as best I could with a wire brush and lacquer thinner. I used Rustoleum Rust Reformer and then a couple coats of Hi-temp Dupli-color. We'll see if it holds up. If not, I'll try something else. Maybe grill paint. | ||
| Ourdee |
SO, If I take mine in like it looks above they will order me a new one? | ||
| Bienhoabob |
"SO, If I take mine in like it looks above they will order me a new one?" I was told one muffler replacement under warranty. Which I did, but it's not a fix, it's a replacement. Second one rust just like the first one. | ||
| Jlnance |
Chrisrogers - That is a great observation. If the corrosion is indeed caused by the contact of two dissimilar metals, it should be possible to protect the muffler cathodically, with a sacrificial piece of zink. I'm not sure what the physical requirements for cathodic protection are. Would it be enough to connect the muffler and the aluminum mount via a zink wire? |
