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Old 05-26-2018, 07:26 PM   #1
popoquira
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Default Can I patch a muffler hole

Hello, my 02 Impreza TS has a hole at back of muffler on the bottom, about 3" by 1". It's the rear muffler and hole is at back end, facing down, probably where moisture gathers.

Is it too big to patch? And if it can be patched what is best technique and material to use?

I'm asking because I've seen lots of postings and ads for various compounds, special paints, fiberglas wraps for muffler holes. But I'm wondering if they can work on something of this size. Car has about 146K and lots of rust and is a spare car at this point. I drives fine, but would like to avoid dropping several hundred $ or close to $1K for repair muffler shop or muffler joint to replace it.

Thanks
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Old 05-26-2018, 07:51 PM   #2
Slim_Jim
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Go to an auto parts store, buy a muffler, cut the old one off unbolt the old one and put the new one on....DIY cost...probably under $150

If a muffler shop around here charged close to $1k just to replace the rear muffler and tailpipe, they be out of business in 6 months.

AutoZone has a Walker replacement for under $100


You could probably patch it, but it won't last long.

Edit: I just looked up the exhaust on a 2002 Imprezza TS, it has 2 hangers and is flanged behind the muffler with 2 bolts. Very easy to change.
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Old 05-27-2018, 11:18 AM   #3
Sour_K
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What the guy above me said is the smart way to do it.

If you want a cheap way, find a friend who is a (good) welder and some sheet metal, have them weld a small square over the hole, making sure it's sealed with the welds. I only suggest this because you were worrying about cash, and this car isn't a huge deal to you. If you want to repair it the right way, do what the other guy said. This would probably work as a cheap (free/case of beer for your welder friend) fix for a while though.
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Old 05-31-2018, 02:07 PM   #4
mcursch88
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can of beer, trim the ends, cut down middle, lay flat over hole, and jb weld.
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Old 05-31-2018, 02:14 PM   #5
cdska
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Quote:
Originally Posted by mcursch88 View Post
can of beer, trim the ends, cut down middle, lay flat over hole, and jb weld.
I did this with an old buick that had the exhaust pipe break in half in a parking lot, with a soup can and a scissor jack. Happy to say I'm still alive today and I'm no longer that stupid
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Old 05-31-2018, 03:20 PM   #6
mcursch88
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Quote:
Originally Posted by cdska View Post
I did this with an old buick that had the exhaust pipe break in half in a parking lot, with a soup can and a scissor jack. Happy to say I'm still alive today and I'm no longer that stupid
I wouldnt say stupid. more like desperate.
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Old 06-01-2018, 01:41 PM   #7
Samurai Jack
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Seems as if you are looking for a cheap solution, given your car's story.

Go to an auto part store and buy an exhaust repair kit. Not very expensive. Lasts about (1) year before you have to re-do it again.

It is basically a bandage that you wrap around the defective area.
Definitely works
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Old 06-01-2018, 01:57 PM   #8
rtv900
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Holes in mufflers in my experience rarely cause failed inspection. On old crappy vehicles I've had I basically end up repairing or replacing simply because the sound gets annoying enough.

So is that the case with you? Or why do you now want to repair it because given that it's a 15 year old car there's no way that muffler just all of a sudden lost a chunk. It's probably been getting worse for 5 years.
Just curious why you feel you need to do something now?
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Old 06-03-2018, 12:59 PM   #9
jd14
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wrap a plastic bag over the exhaust hole
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Old 06-04-2018, 11:23 AM   #10
Samurai Jack
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You do understand that the plastic bag will melt, right?
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Old 06-06-2018, 09:17 PM   #11
thepotsy
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Default

Quote:
Originally Posted by Slim_Jim View Post
Go to an auto parts store, buy a muffler, cut the old one off unbolt the old one and put the new one on....DIY cost...probably under $150
While you won't cut the muffler itself off, a 2001's flange bolts will probably be some sort of rusty blob by this point. You will need a cutoff wheel to get them off. A Dremel will suffice.
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Old 06-09-2018, 03:10 PM   #12
Daniel Dudley
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I've welded them. I have cut them off and put cheap box mufflers on. Cheap mufflers can sometimes be like 20 bucks.
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Old 06-09-2018, 03:12 PM   #13
Daniel Dudley
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Old 06-09-2018, 03:13 PM   #14
Daniel Dudley
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Oh look, polished stainless steel, 38 bucks... https://www.carparts.com/details/Sub...E&gclsrc=aw.ds
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Old 06-10-2018, 02:38 PM   #15
popoquira
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Default Muffler

Thanks for all the suggestions. Car has passed inspection noise from the hole is bothersome
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Old 06-14-2018, 08:12 PM   #16
eclone
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its a GD. stock NA/WRX/STI mufflers are dime a dozen if not free. post a wtb your local forums/fb group etc dont bother fixing it
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