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Saturn Muffler - Patch job

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Sledgstone

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So I noticed my muffler was sounding louder than usual and I knew there was a small hole right on the end of it. So I bought a tube of muffler/exhaust patch goop and took pictures of my patch job. Make sure your car has been off for quite a while before doing this yourself. Your exhaust pipe and muffler should be cold when using this stuff because heat will only harden the goop too fast and you risk burning yourself. So yeah, to do this job yourself, all you need is the following:

1 tube of Exhaust system joint & crack sealer

(purchased at NAPA for $2.95 or so)

1 throwaway latex glove

(purchased at NAPA or walmart, an entire package for a few dollars, usually near the toilet scrubbers at walmart or auto chemical section)

1 can of brakekleen or any brand of spray on brake parts cleaner (all you need is a couple sprays out of it for this). ($3)

Here is the hole in my muffler.

muffler01.jpg

Here is a pic of the Exhaust system joint & crack sealer that I used. Autozone or Advance Auto Parts probably have the same brand or something similar.

muffler02.jpg

Here is the hole in my muffler after I sprayed it with some brakekleen to get the harmful chemicals off it. Then I let it air dry and then sandpapered it lightly to remove excessive rust or grime. Then I sprayed it again with more brakleen and let it dry once again so the goop will stick good.

muffler03.jpg

And just as I was about to put the goop on, I noticed this hole, and yes those are metal coat hangers holding up my muffler, the strap rusted away about six months ago.

muffler04.jpg

LMAO, holy shit! No wonder it got so loud! X'D

muffler05.jpg

So I put on the throwaway blue rubber glove and smeared some sealer onto the hole.

muffler06.jpg

I also cleaned, sanded (And wow, after rubbing it lightly with the sandpaper it became an even bigger hole) and then cleaned the huge hole and smeared almost the entire tube all over the hole. Since the sealer goop starts stiffening rather quickly, it was easy to just keep applying blobs to the edges of the hole, let it harden slightly and then just keep building on that edge until it covered the entire hole.

muffler07.jpg

Because it kept wanting to cling to my finger and reopen the hole when I touched it, I had to let it dry for an hour and apply another layer over top of it to finish the patch.

muffler08.jpg

I then let it sit over night and it was noticeably quieter the next day. Not normal of course. If all I had was just that little hole, once it was patched, you would think the muffler was new. But that huge gaping hole affects the noise the muffler makes now. I'll have to get a new muffler soon, but at least until I do it doesn't sound like I'm driving some old diesel truck down the road. X'D

Btw, if you have a small hole like the one on the end of my muffler on any part of your exhaust pipe, do this quick easy fix yourself and it'll cut back on alot of noise.

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