Muffler Repair Recommendations [ 1997 Volvo 850 GLT ]

[1997volvo850]

I know that quite a few people are going to respond "just buy a new muffler" but taking my
car to a shop is as comfortable for me as buying a car is (dealing with car salesman). You're
thinking I'm a cheap SOB. If you are around when my wife is present you'll wonder if my middle
name is SOB.

A few years ago (at least) my Volvo guy tells me my muffler has a long slice in it and needs
to be replaced. I think it was going to be $400 or so (plus the extras when things go wrong).
I ask how long before it must be replaced. He says a while (big mistake) so here I am with the
same bad muffler.

The long slice in the muffler does not generate a lot of noise. I mean that it doesn't sound like a
car that really needs a muffler. So I've held off for a few years but now realize that I may be
able to do something myself, if only to reduce the noise, that is cheap and effective.

I was planning to clean up the rust and JB Weld a thin piece of sheet metal to fill the crack.

When I was browsing in Advanced Auto Parts yesterday I saw this putty like substance
that is actually intended to repair cracks in the muffler/exhaust system. I'm thinking to myself
that this can't hurt too much.

Has anyone tried any of these putties for repairing the exhaust system?

What can I use on the rust (rust inhibitor) that will not result in a fireball when I go for drive?
Is there something for rust that will hold up to high heat?

Here are a few pictures:

Crack in Muffler

Closer View

[volvomileage]

hmmm it looks too far gone i would change it

had the same and i just replaced the whole thing

if you want to gamble try sanding out the rust and welding if the metal left is too thin its not going to work or fill it up with muffler putty but i fear its not going to last its a very temporary fix

you can get the muffler part for about 200$ and do it yourself its not that hard shop around..

metal seems to be too far gone

[shiloh51933]

JB weld will hold if you do it right, meaning clean the up the best you can and use proper amount to fill slice. Ive used that stuff on oil pans and people I know have used it on buses and big trucks. You already know that you should replace but I understand your trying to fix cheaply so I would swear by JB weld if applied properly.

[1997volvo850]

hmmm it looks too far gone i would change it

you can get the muffler part for about 200$ and do it yourself its not that hard shop around..

metal seems to be too far gone

My novice status is starting to shine through. I always thought that the muffler system was
welded together. I don't own a welder and would not consider spending a few hundred for a
welder to use once every 7-10 years. Have you blasted my false myth to pieces?

Are you saying I can replace the muffler with normal hand tools? Which brand muffler is best?
I'm assuming OEM is less critical here.

My other fear (of taking it to a shop) is that every component the tech is able to put a
hammer through ends up needing to be replaced.

I've done a complete timing belt and water pump replacement, plus now I've done my
rear brake pads. I'm so proud of myself. What level do I need for the muffler system?

I guess my concern is, with the rust, I may end up causing more problems by disturbing
things. Since I didn't find any muffler tutorials I was thinking this is not a DIY project.

I may try to MacGuiver it to see what it's like to work with the high temp putty and how
they hold up.

My list of things grows longer...

Thanks

[volvomileage]

if your muffler system is original it should not be that hard

usually theres a clamps hoding togther the catalytic converter pipe and the exhaust muffler pipe

here a link to that part
http://www.fcpgroton.com/product-exec/p ... ory_id/130
and the muffler is here

http://www.fcpgroton.com/product-exec/p ... ory_id/130

either you remove clamp if too rusted just grind out the clamp' s bolts and put a new clamp the clamp holds both pipe's end collars together
or choice number two when one of the collars is too far gone is to cut off collars from pipes and replace with a muffler pipe to do the joint
you might in this case use welding to assure its air tight or use 2 standard muffler clamps to each end to tie down and secure the joigning pipe
either way you leave the holding rubber bands untill old muffler is free from the connection point, you will be able to push back muffler pipe and have a play
then to install the new muffler install it on the rubber bands before and then tie both ends (muffler pipe to catalytic converter pipe) with a clamp or muffler pipe at the joint. if you have someone to give you a hand it will help as the muffler is a tad heavy

sorry i am visual sometimes its easy to see but harder to tell

it takes about 15 to 20 minutes a muffler shop to change mufflers especially with oem style mufflers

[igel513]

If u don't want to buy new, go to junkyard- there's tons of them out there.

[Ozark Lee]

Check with the guys at OBX racing. They sell some high performance systems for less money than the ebay aftermarket guys charge and their stuff is very high quality. Volvo is largely ignored on the website in favor of the ricers but give them a call - they have everything from the manifold back for Volvos.

...Lee

[JRL]

That's a big one but it IS possible to repair it (for a while at least)
FURNACE CEMENT
Follow the instructions and please grind off the rust before you start and after you apply it, IDLE the car for at least 15 minutes to cure the cement, do NOT rev the engine up, it's not cured and you could blow it off until it hardens in 10-15 min.

IT WORKS!

[igel513]

Where r u located at. Just came from junk yard bought a tire for d s70 (tot. cost = $18+change/tire) plus the mounting and balance fee of $15/tire. Saw a couple of volvos there but just one 850. Mufflers are intact but they don't sell the cat. If u r nearby, I could get you one. I'll be there this coming sat. to get more tires hoping for new arrivals. Email me - [email protected].

[Craigd2599]

There's cheap and then there's stupid. Spring for the new muffler Ebenezer.