$85 to $142 for a new muffler? try this temp fix for $10....

[g2barbour]

I wasn't happy with the prices of new mufflers, so i wanted to take my time shopping around for an aftermarket setup until after I completed my '03 grand prix supercharged 3.8 implant into my '99 SLE next weekend. So I went to the hardware store bought some pipe clamps for $10, and acquired the door skin sheet metal from the back of a local auto shop. Then I hammered it all out, scraped it off, cut 6" off the end, and wrapped my muffler. Done. This should hold until I find what I really want (or until I get it inspected)... And yes, I do know this is white trash at its finest.

















Hear it run in this video: https://www.facebook.com/photo.php?v=733920033295170&l=3115671752042754233

[nos4blood70]

Well that's one way to do it!

[bs009]

soooo... how much does it rattle?

[g2barbour]

See the video, no rattle

[bs009]

Looks like I missed it.

Not bad

[MattStrike]

I've done something like that before, lasted about a year.

[g2barbour]

A year? I'm surprised. I thought about welding it, I bet that would last longer. I have to get it inspected in September though, so I probably won't push it past then be I doubt it would pass. As soon as I get my new engine in I'll be on the search for a new one anyway

[g2barbour]

So I finally broke down and ordered a WALKER 21427 muffler from rockauto.com for about $50 after the $50 rebate that is going on right now. But before I did, there was some exhaust fumes getting past my straps, so I took the opportunity to make my old muffler the first job for my new MIG welder. Take it easy on me, Im brand new to welding. This actually worked really well. Because it only needs to last a few days I used the same scrap and welded right to the rusty muffler. I did grind/wirewheel the end seams though. I would have just left this until I had to buy a new one, but the muffler I ordered is for the SSEi, and I am doing an L67 transplant soon, so the one on order is in preparation of my future upgrade. Also relevant: I recently dropped my fuel tank 4x playing with the fuel pump and upgrading it to the high flow double inlet version found in the grand prix GTP, which was a lot of activity for my exhaust system, which I twisted, pryed and torqued out of my way. I quickly became clear that the welded union between my cat and resonator was rusted and leaking. I had to cut out the weld and clamp the sleeve end of a 2.5" exhaust extension into the gap. I did this because I was told that in Pennsylvania if I weld my own exhaust system it will not pass inspection for some reason. Any thoughts on this? I despise the clamps, but its nice being able to disassemble my exhaust to work on my car. Also, the extension was galvanized and Im really not looking forward to sputtering and fumes when welding on it. And yes, I am planning on welding on my new muffler when it arrives. Just going to hope nobody makes a big deal about it. There really isnt another way to repair it.

[coop8070]

I used a soup can and hose clamps to patch my old Suzuki gs450t muffler. Lasted 2 days...

[g2barbour]

I'm just glad I got a mig welder, I will never need to settle for clamps again!

[g2barbour]

I received my new muffler, and it is much smaller than the original, but all the pipes appear to be the correct size/location. Overall, the outside of the stubs on my new one are about the same as the casing width of the old one, so it looks like I can patch it in if I cut right against the old casing. I would like to hear some feedback as to whether or not this is right before I commit to cutting, as it actually works pretty good now.

[MattStrike]

aftermarket muffler companies also make a matching tail pipe to make up the difference, but if you have a MIG you can make anything work.

[g2barbour]

ok. thank you!