Muffler Resurrection

[Reserector [Veteran Member]]

Problem #1:
My muffler has loose baffles inside that are rattling around.
Problem #2:
The muffler is loud and embarrassing.
Problem #3:
My earlier repair is no longer effective. That repair went as follows: I identified where the rattle was, drilled a hole through the muffler, then used a long bolt and a nut to compress the muffler's shell. It worked for a while, but the problem came back.
Problem #4:
I have no money. I am, however, blessed with a working welder, some acelylene, and a little bit of oxygen.

I can rebuild it. I have the technology. I can make it better, stronger, faster.

After removing the rear section of exhaust, I slice into it.


I find the loose pieces of what used to be a baffle.


Here, I have highlighted the old welds in white, so you can see where is used to be. The exhaust is supposed to go around the ends of a V-shaped plate. Without that, the exhaust goes straight through.


I made a new baffle out of some scrap, including part of the original baffle.


This is the piece of scrap that I selected for the new outer skin. (It said Murray on the other side. )


Here, I have welded the baffles and prepped the case for its new skin.


I marked and drilled a number of holes in the new skin. I will plug weld through these holes and into the baffles. This must be done to prevent vibration and expansion.


After positioning the cover, I make several of the plug welds to hold it in place. Using the "hot tack" method, I work the skin down smooth. I refer to this as "tack it and smack it."


I then cleaned the whole area and welded the remaining plug welds, then welded the outer edge.


I was out of BBQ black and high heat orange, so I used up the last of the Torquin' Teal engine enamel.

[yazoomud88 [Veteran Member]]

Yeah Res those flowmaster mufflers are bad about falling apart on the inside a guy at the muffler shop told me they burn out is what it is. I have the Cherry Bomb muffler made like it it's made better. But, u did a great job man it's probably better welded now then it was from the assembly line.

[mdawg4x4 [Veteran Member]]

I am surprised you didn't make a new one out of an old dishwasher!

[dvdswan [Veteran Member]]

I am surprised you didn't make a new one out of an old dishwasher!

no that was the inner bed panels ok well close enough to a dryer tub

[Reserector [Veteran Member]]

Yeah Res those flowmaster mufflers are bad about falling apart on the inside a guy at the muffler shop told me they burn out is what it is. I have the Cherry Bomb muffler made like it it's made better. But, u did a great job man it's probably better welded now then it was from the assembly line.

That baffle actually WAS burned out in the middle. I have a double layer at the bend, where the original part burned out. It should hold up for a while.

[Post Hole [Veteran Member]]

Hey thats the same color as my water pump. Now where did I get it painted at. LOL

[BigCountry [Veteran Member]]

uumm...why?....mufflers a cheap!! paid $40 for my flowmaster

[Reserector [Veteran Member]]

uumm...why?....mufflers a cheap!! paid $40 for my flowmaster

Partly because I am flat broke and partly because I can.

[BigCountry [Veteran Member]]

aww, c 'mon res, your an engineer, and im a maint. man and even i can afford a new muffler!!!.....but a penny saved is a penny earned!!!.....good lookin work though, ive got an exhaust leak ive got to fix just afraid of ringin off the exhast studs

[roponop [Veteran Member]]

Good job on the repair. It’s nice knowing you can fix anything given time & material isn’t it?

The acetone was a little close for my taste though. Be careful, I once saw the aftermath of a can of spray paint poping after hot slag fell on it.

RP