Muffler hole
My jeep Cherokee 1991 makes a rattling noise in the back, and the exhaust is loud. I looked at the exhaust and found what it shows in the photo. Where the pipe meets the muffler, there is a hole that spans halfway around. How would I patch this? Would muffler putty work? Also how long would the patch last? I would probably be able to replace the muffler in about 6 months, but I don't know how to get the pipes disconnected since they are probably rusted together.

 

So we sell that putty at the store.
I think this is the stuff but the packaging looks different then what we have in the store.

https://www.napaonline.com/en/p/PTW7...t=muffler+weld

Not being there I can't be sure.
Anyway I just assumed that stuff was crap but happened to mention that to one of the counter guys one day.
They said it actually works pretty good.
Whether it will for what you need it to do or if the counter guy knows what he is talking about is another thing though. LOL.
Hey for what it costs what do you have to loose?

 

Just replace the muffler. Problem solved for another 15-20 years lol

 

Cut the pipes if stuck and use these...


Evil Energy stainless exhaust clamps

they make them in butt and lap joint style, note the supplied bolts are crapola, low grade which strip the threads if tightened too much, I swapped oit the bolts and nuts with high grade hardware, the rest of the clamp,is good stuff.

you may want to invest in more muffler hangers, as it is the weight of the muffler dangling which tends to tear open the muffler like yours. I weld so I added a couple gussets to the muffler to brace the inlet and oulet pipes to the end fold on the muffler to prevent the inlet and outlet pipes from flexing

as for putty, it may fill that hole, but so long as the muffler flexes to the pipes, it too will crack open eventually, unless the inlet or outlet pipes are braced or you add hangers

Cheapo thin mufflers need extra hangers to prevent what happened to you.

I prefer the clamps linked over welding, as it allows you to easily replace components without cutting and welding.

 

Yeah, the putty might work for a while but it will eventually break and the thin sheet metal on the back of the muffler will continue rusting out. Off the shelf, bolt-on walker parts are relatively cheap and easy to install. I love the wide band clamps because they don't crimp the pipe, allowing you to easily loosen and realign things as needed, and you don't need to torque the heck out of them to get them to stop leaking like the u-bolt style.

 

What tools would I need to cut it?

 

If you have access to a drill, I'd go to a hardware store & ask for a cutting wheel for a drill. Otherwise, a hacksaw. Also, be sure to buy safety glasses. Personally, for something like thus, I'd prefer a face shield.

 

A hacksaw, get a fine metal cutting blade for it, and yes on the safety glasses, even for a hacksaw as you will be sawing overhead.
power tools like a Sawzall will work too, be faster. but a hand saw will get the job done. you want a nice straight cut, so mark the cut line with masking tape wrapped around the pipe. a few drops of motor oil on the saw blade applied every now and then will make cutting easier and make the saw not go dull so fast. if you can unbolt the part and cut on a bench, perhaps in a vice, or clamped with C clamps, or have a helper hold it will make the job easier, specially if you cut by hand, as under the jeep maybe awkward.

 

further to that, just take it to a muffler shop, those guys are magicians with mig, and will weld in a new one in 5 minutes

 

I typically recommend against the big chain muffler shops. They tend to only order and install oem parts and have no idea how to bend a pipe. Local mom-n-pop shops are much better. Local guy who works out of his garage charged me $100 for a muffler on the wife's truck. $50 muffler and $50 labor.

 

I totally agree, have known my exhaust guy for over 40yrs, he is 5 minutes down the road, and I always pay cash

When my Cat went, I just Ebayed a 2-1/2" universal item, and he welded it in for $50

it would have cost me more for parts if I bought the Cat through him

I could do the job myself, but this is just one case where it is easier to pay someone else

(The local chain muffler shop employs guys direct out of prison) lol

 

It looks like it's the muffler case itself that's rusted so there's nothing a clamp could do. Grind off the clamp and outer muffler connector and slap on a new muffler.

 

35 bucks for a Walker

 

i wouldn't screw around with trying to jerry fix what you have. just do as these guys say, and simply replace that muffler. you may need a new tail pipe, they're quite cheep too, but if you can use what you got, then make it work.
if you can't do the job yourself, then take it to a muffler shop. it won't break the bank. heII, i was quoted only a couple hundred to put duals on my Dak a few years ago.
if you know anybody that has an account at a jobber, get them to order what you need. it's usually half retail price. throw him a few extra bux for helping you out.