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I had the same problem with mine. There is a metal piece in side of the exhaust pipe that can break loose and resonate (vibrate) with reving of the engine. The cheap and easy fix is to torch a small hole in the exhaust pipe and then weld the loose metal piece to wall of the exhaust pipe then weld the hole shut. Mines been good since. Please post if this is not the problem.
JB Weld
If the pipe is in good enough shape you can weld over the hole, BUT If there is one small hole rusted in the system it is a good sign the pipe is rotted. There will be many other holes soon. There are probably more holes than you know about. You will probably have to have an exhaust shop put in a new pipe for you.
by having a exhaust shop weld on a y pipe then just run the dual pipes out the back
No. It is only efficient up to 500degrees Fahrenheit and most of the exhaust system will normally get hotter than that. You need proprietary exhaust repair material or a professional weld.
No. Helicoil
There might be rules and laws involved in this, but generally when a pipe gets a hole in it corrosion is the reason and a replacement is cheaper and the correct way to do it. If the pipe had some mechanical damage like driving over a sharp object a weld repair is possible and can work fine. Nothing lasts forever.
A butt weld is a weld made between two straight cut profiles , a socket , or plug weld is made between a surface and a hole.
Gi weld not recommended . Because of gi coationg will be spoiled out . Puncture will be occur on the pipe weld .
Very likely to leak, zinc in the GI pipe will be contaiminating the weld and thus you cannot get a good weld.
You could try J.B Weld or use exaust tape to temporarily fix the problem.
maybe u could try and use some copper tubing you could cut the flange off your old pipe and weld it to your homade pipe. make a manifold by tracing the stock pipe and then trace it on some 1/8in steel and cut it out with a jigsaw, tourch, plazmacutter or what ever you have then drill holes for the bolts. mount that on the engine then find yourself a pice of tubeing that fits the manifold and tack weld it on, take it off the engine then fully weld it. or gut the stock pipe and drill out the outlet to have a tuned exhaust pipe make your pipe bolt it on, use house paint and paint your exhaust(it dousn't matter of the colour trust me) ... wait until dry and start your bike there will be a nice ring burnt off your exhaust, mark and cut there ...now take off all the paint and now you have a preformanced tuned exhaust