10

Muffler Replacement

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booneylander
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BBBLLRRPRPRPPSSLAK

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Nov 15th 2014
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That's the sound my truck was making. There was really no doubt what was wrong. The tailpipe was pointing at a crazy angle, and everything was noisy as balls. So I figured I could do my poor truck a favour and try and remedy the situation.

Now let me say this was no small proposition. Here in Hawaii I didn't have much tools, so I set out and rented a Lincoln wire-feed welder and a Makita sawzall from Home Depot. It as big dolla dollas to rent, but I figured I would replace pretty much everything from the headers back and make it all up nice, so it'd be worth it.

The next step was hitting up all the automotive supply stores for materials. This was a big disappointment. I couldn't find the normal selection of straights, 90s, 45s, hanger stock etc that I would need to do it up the way I liked. No one even had "sport" mufflers over the counter. And ordering something? Forget it. 6 weeks ait as the norm.

Sufficiently distraught, I ended up buying a replacement OEM muffler that O'Reilly's had in stock (random), and a couple adapters to hopefully be able to cut and splice things together. Oh Hawaii how you like to make working on stuff difficult.

I should stress that I wasn't that worried about the exhaust noise and I COULD have ordered the stuff I needed, to replace it weeks later, BUT my annual safety and plate sticker were both expired, so I really didn't want to be more conspicuous to the po-po than possible, and I couldn't renew the plate without the safety, or the safety without fixing the exhaust. So there it is. OEM replacement (barf!!).

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  1. Here's the stock looking muffler looking like a pile. It's clearly already been replaced at some point... poorly.
  2. As you can see the piss poor patched up hangers were fully functional. At this point I just went to town on the muffler with the sawzall, trying to keep as much pipe as possible to have something to weld the new muffler to.
  3. Old vs. New 4+5. Holding the muffler up while simultaneously aligning the end and welding it by myself, wasn't too obvious, so I had to come up with a temporary support.
  4. All welded in with a bit of extra pipe o make everything work. The welds were terrible. But hey at least it didn't leak! I should mention that I didn't have any steel rod to remake the hangers, and the parts places couldn't get me an OEM replacement at all. I did manage to put on one of those cheap little hangers using a mufflr clamp and a bolt to hang it off the frame. It worked ok, but I'm certainly not proud of this install. Hawaii got the best of me this round!

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Feb 2015
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Muffler Replacement

q20v upvoted

booneylander published chapter February 22nd 2015

booneylander uploaded 11 images

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