Walker's World
Words & photos by Geoff Walker

So you've run your four-banger for 10-15 hours and things are starting to get a little noisy and a little slower. Read on while we take you through the rules of the re-pack...
For this little job I'm using the DEP power pack kit that comes complete with packing, a 5mm drill bit, packing tube, heat strip sticker, rivets, instructions and, most importantly, a sparkly DEP sticker for your good-as-new tickety tail-pipe!

geoff's toolbox
checklist

These are the tools you're gonna need for repacking your tailpipe.

- Drill
- Rubber mallet
- Heat gun
- Rivet gun
- Small punch
- Stanley blade
- Silicone
- Vice
- Carb cleaner (essential for sticker removal)
- Duct tape

 

 

 

 

  Pack up !
By now you should know why your four-banger's tail-pipe needs regular prepping - so here's how to do it...
 


Okay, got
your tools sorted? Let's do it... With a four-stroke silencer you should pack it from the end cap although some stock part packing (eg Kawasaki) can be bought as a single unit and placed inside from either end.

With a 5mm drill bit in place just simply drill the rivets out - if they start to spin and not cut give 'em a wee peel over from the side with a small punch to allow the drill to get some purchase. The end cap can be a bit of a bitch to get out - I use a Stanley blade to cut away as much of the sealant as possible and then get my heat gun on it to gently warm the puppy up. This tends to do the trick.

With the cap removed you need to use a hook to whip all the old packing out of the body and cap. Replace the packing in the end cap if required but don't pack it too tight, just use a nice even amount.

At this stage I check to make sure there's no damage to any of the internal parts of the pipe - if all's tickety-boo then proceed!
Tape the end of the core as shown - this stops you getting any packing where you don't need it and generally makes the job easier and less wasteful. Now get a good handful of your packing material and go all creative on it.

Make a doughnut shape (mmmmmm, doughnuts) and slip it into the pipe body.

 

 


Next use the packing tube - or a similarly technologically advanced weapon of choice - to pack the material in real tight.

Repeat this process twice more and then pack more loosely up to the end of the perforated core.

Remove all the tape at this stage and silicon the fitting surface of the end cap before slipping the puppy back into its rightful place.

You may need to give it a little persuasion with a rubber mallet but be careful not to damage any parts. Get the rivets in place and squeeze each one up just a little bit to start with to make sure the holes are all lined up correctly.

When they are, finish the riveting and then lick your finger and smooth the silicon to create a nice and tidy seal around the joint.
The DEP comes with a handy heat-sensitive sticker - slap this on and you'll know when it's time to do the job all over again. Cool eh?

Job done!


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