How to patch a muffler

With the jack in the correct space, jack up the car until it is high enough to safely work beneath it. Never work beneath a vehicle supported only by a jack. Inspect the exhaust piping. From beneath the vehicle, inspect the exhaust piping starting at the front of the vehicle and working your way back.

If you have an idea of where the leak may be, you can begin your inspection in that area. Look for signs of damage such as scrapes, rust, cracks or holes. Rust is also a common cause of exhaust leaks. If rust penetrates through all the way through a pipe, it will result in a leak. Cracks in the piping are another common cause of exhaust leaks. Start the vehicle to help locate leaks. If you are unable to readily identify the source of the leak with a visual inspection, have a friend start the vehicle.

From beneath the car or truck you should be able to spot the leak as puffs of exhaust smoke escapes from it. Keep your hands away from any moving parts. Make sure the vehicle is in park for automatic transmissions or is in neutral with the wheels chocked standard transmissions before starting it.

Assess the extent and type of damage. Depending on the type of damage you identify on your exhaust piping, your repair options may vary. If the exhaust piping is covered in extensive rust, that entire component of the exhaust may need to be replaced by a professional.

Small scrapes or holes can be addressed without cutting out portions of the exhaust. Larger holes will need a piece of aluminum in conjunction with an epoxy to seal.

Method 2. Scrub the area surrounding the leak with a steel toothed brush. Because the exhaust is located on the underside of the vehicle, it often gets caked with mud, dirt and rust. Once you locate the leak, use a steel toothed brush to scrub the area surrounding it. Most repairs will not stick or seal if done over dirt and grime. Make sure to wear eye protection while scrubbing the area to prevent debris from getting in your eyes.

Use sandpaper to prepare the surface of the pipe. Once you have scraped off most of the dirt and grime, take a piece of fine grit sandpaper and use it to scrub the portion of the pipe you need to repair. Sandpaper will remove the last bits of dirt as well as creating tiny micro abrasions in the metal to help the tape or epoxy adhere to it.

Roughing up the surface of the metal will create a stronger bond for the patch. Wipe the surface down with acetone. Once you have brushed and sanded the pipe around the leak, wipe the area down with acetone to clean it and help the exhaust epoxy bond to the metal.

Acetone is the primary ingredient in nail polish remover, so using nail polish remover will work well for this purpose. You can purchase acetone in the cleaning chemicals section of many retail stores, or nail polish remover in the health and beauty sections.

Determine if the hole is small enough to be sealed without a patch. Small cracks or pinholes can be sealed using just epoxy or exhaust tape, but larger holes will need a patch. If the leak is a thin crack or small hole, you can proceed without purchasing or making a patch to help. If the hole is larger, you will need a patch as well as epoxy. Wrap the exhaust tape around the pipe. If you are using exhaust repair tape, wrap it all the way around the pipe, covering the exhaust leak with at least two layers of tape.

Make sure to wrap the tape around the pipe for a few inches to either side of the leak as well. Different kinds of exhaust repair tape will require different application methods, so be sure to read the instructions thoroughly before you begin.

Other forms of exhaust repair tape needs to be wet before applying. You can purchase exhaust repair tape at most auto parts stores. Mix the epoxy together and apply it to the leak. If you are using epoxy to seal the leak, mix the two parts together using a wooden dowel. Once the two parts are mixed, it will begin to cure immediately, so apply it to the leak quickly. Dab the epoxy over the leak, then use the wooden dowel to spread it around the area. Leave a thick layer of epoxy over and around the leak.

Different types of epoxy have different curing rates, so read the instructions on the package to know how long to allow it to sit before driving the vehicle. Method 3. Determine the size of patch needed. You can purchase exhaust patch kits from your local auto parts store, but cutting up a piece of an aluminum can will actually do just as good as job at serving as a patch for a larger exhaust leak. After scrubbing and cleaning the area, determine how large the patch will need to be to cover the leak and leave at least a half inch or so of extra material beyond the hole itself.

If you purchase a patch kit, make sure to read the directions to assess the size of a leak the kit can fix. Cut an aluminum patch to fit over the leak.

Use a pair of heavy duty scissors to cut your aluminum can into a patch large enough to cover the leak. You may also choose to wrap the can around the pipe. For smaller leaks, you can simply cut a circle of aluminum that is a half inch larger in diameter than the hole. Wrapping the can or patch all the way around the pipe will provide the best seal. Cover the area surrounding the leak with epoxy. Just as you would seal a leak with epoxy, mix it together and apply it to the pipe around the leak.

Make sure to apply enough epoxy to create a seal for the patch, but don't apply so much that the epoxy begins to drip into the exhaust piping. If you are going to wrap the patch all the way around the pipe, apply most of the epoxy to the area around the leak and a lighter coat all the way around the pipe.

Place the patch over the leak. Either place the small patch directly over the hole or wrap a large patch all the way around the pipe. If wrapping the patch around the pipe, make sure the middle of the patch is over the leak itself. Make sure none of the leak extends beyond the sides of the patch. Apply epoxy over the patch. Use a wooden dowel to apply more epoxy to the edges of the patch.

You may even choose to coat the patch itself with epoxy. This will help hold the patch in place as the epoxy dries while also creating a more solid seal to prevent any exhaust from leaking. If you wrapped the entire pipe with a patch, you do not need to coat the entire patch, but pay special attention to wear the patch meets on the opposite side of the pipe from the leak.

Secure a large patch in place with hose clamps. If you wrapped the patch all the way around the pipe, use two hose clamps to secure it in place and ensure a tight seal. Place one hose clamp on either side of the leak on the pipe, then use a socket wrench or flat head screw driver to tighten the clamps into place over the patch. You may want to clip the excess ends off of the hose clamps once you are done.

Did you know you can get answers researched by wikiHow Staff? Unlock staff-researched answers by supporting wikiHow. Not Helpful 1 Helpful 2. Not Helpful 2 Helpful 1. Not Helpful 0 Helpful 0. Not Helpful 3 Helpful 3. The amount of time this repair will take varies depending on the type of patching material you opt to use.

Some exhaust tape or epoxy can set and cure very quickly, while others may take over night to dry. Read the instructions on the package to be sure. Not Helpful 4 Helpful 7. While you may choose to cut a portion of a damages exhaust tip off, cutting off your exhaust anywhere closer to the engine may cause functional or legal issues. Cutting off your muffler, for instance, can make your exhaust extremely loud and may not be in keeping with emissions laws for your area.

Not Helpful 15 Helpful 8. You should take it to professional muffler shop they will be able to provide you with anything you need. Not Helpful 9 Helpful 4. As you operate the vehicle, the heat in the exhaust will melt the patch or tape and seal over the patched area after a few miles of driving. For a more involved type of repair like installing a pipe extension to replace a rusted or broken piece of pipe, you will need to make some preparations:.

You can also use ready to install pipe adapters if you find the correct diameters for your application. Watch the next video to see how you can install them. Learning how to fix the exhaust pipe or muffler—including broken pipes or small leaks—is not as difficult as you might think.

A close visual inspection of the damaged area and a visit to your auto parts store to check available solutions will help you perform this repair job at home in most cases. This relatively simple fix can solve your exhaust leak, pollution, and noise. So taking care of the problem on time not only saves you money in car repairs but also stops toxic gases from reaching you and anyone else riding with you.

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