Hole in Muffler

[OlliesLRover]

Disco 94 V8i Auto

Noticed a hole in the middle muffler a week ago, looks like it had been cut with a sharp knife (sharp rock) about 2" long 1/4" wide.

Muffler in very good condition no rust or dents.

I got some Permatex muffler putty and followed the instructions to the letter - cleaned area - pushed putty into the hole - let engine run for 10min - left to harden over night ect ect.

2 days later putty had started to bubble and crack, 3rd day gave putty a tap and it started falling out.

Any advice on something that will work.

Regards
Rich

[Scouse]

If you really want to keep the muffler, then have a patch welded over the hole.

[redrovertdi]

or rivet a bit of can over the hole with some putty inbetween, best bet is to replace the muffler with a straight pipe.

[SouthOz]

Steel patch riveted on with some RTV silicone under it will get you out of trouble.

Dave

[OlliesLRover]

If you really want to keep the muffler, then have a patch welded over the hole.

Interesting, I was under the impression (muffler guy) you couldn't weld mufflers??

[OlliesLRover]

or rivet a bit of can over the hole with some putty inbetween, best bet is to replace the muffler with a straight pipe.

How loud will it be, as I'm well on the wrong side of the loud noise barrier:D

[Scouse]

Interesting, I was under the impression (muffler guy) you couldn't weld mufflers??Sure, they're made of thin metal but anything steel is weldable.
The standard muffler wasn't stainless or anything fancy so welding it is easy enough - the rust holes at the end of mine get welded up every couple of years or so.

[redrovertdi]

not much louder at all and your turbo can expell gasses faster with less restriction, you still need a back muffler to be legal in QLD

[OlliesLRover]

Thanks, at least I now have a couple of viable options.

Regards
Rich

[seano87]

not much louder at all and your turbo can expell gasses faster with less restriction, you still need a back muffler to be legal in QLD

Its a V8 according to the original post - no turbo.

Not sure how much louder the v8 is without middle muffler? Probably bigger change in noise though with the v8 compared to turbo as the turbo suppresses a fair amount of noise in the first place.

Sent from my Galaxy Nexus using Tapatalk 2

[shamat]

If its V8 and auto it w I'll drone a bit with a straight through muffler. Mine does.
Manuals don't drone half as much. Either way the V8s with a straight through pipe do sound good. :)

[OlliesLRover]

Sure, they're made of thin metal but anything steel is weldable.
The standard muffler wasn't stainless or anything fancy so welding it is easy enough - the rust holes at the end of mine get welded up every couple of years or so.

Who done your welding for you, I have been to 3 muffler places and they say they can't do it, I suspect they want me to spend $200 on a replacement.

ps: I live approx 3/4hr from your area.

Regards
Rich

[bee utey]

Who done your welding for you, I have been to 3 muffler places and they say they can't do it, I suspect they want me to spend $200 on a replacement.

ps: I live approx 3/4hr from your area.

Regards
Rich

I wouldn't bother, although a master welder using TIG or oxy acetylene could easily weld it, the metal is very thin and prone to fatigue cracking. A piece of sheet metal, pop rivets/self tappers and high temperature silicone sealant would be a far better solution for patching the bottom of an old muffler. Let it all cure for 24 hours before driving a siliconed repair.

[Scouse]

Who done your welding for you, I have been to 3 muffler places and they say they can't do it, I suspect they want me to spend $200 on a replacement.

ps: I live approx 3/4hr from your area.

Regards
RichI do my own with a little MIG welder.

If it's a straight weld job, I can have a go at fixing it for you.
I don't have any scrap sheet metal around to make a patch though.

[OlliesLRover]

I do my own with a little MIG welder.

If it's a straight weld job, I can have a go at fixing it for you.
I don't have any scrap sheet metal around to make a patch though.

Thanks for the offer, I have had another go at repairing it via the piece of sheet metal, pop rivets and high temperature silicone sealant as suggested by "bee utey" and others, so will see if it lasts longer than 3days this time.

[OlliesLRover]

Here is my latest attempt (3rd time lucky I hope) to fix the muffler - (see pic).

Found a bit of roofing tin under the house and used Maniseal exhaust cement as a sealant and heaps of pop rivets of various sizes to give it extra strength.

May have to put some more rivets down the bottom but will see how it holds up first

Regards
Rich

[Scouse]

I can't see why that won't work, it'll probably outlast the muffler :).

[OlliesLRover]

I can't see why that won't work, it'll probably outlast the muffler :).

I ended up putting another dozen rivets in just to be on the safe side, just got to remember not to go over any pay as you go weighbridges:p