15 + 23 points
Unconventional Patch by Wetdryvac
September 9th, 2009 3:41 PM
Target: Re-attach muffler to exhaust system on a 1994 VW Jetta III.
Usual Materials: High temp paint to stop rust.
Unusual Materials: Chair bolts, fencing, vacuum extension from a 1940s electrolux.
Tools: Wire cutters, vice grips.
Procedure: Jack car, examine muffler hangers for stability. Measure diameter of exhaust from muffler intake and muffler entry. Search house for some sort of metal tube to splice in. Find 1940s electrolux vac piece with no actual vac anywhere to be found. Get under car, slide into pipe from manifold to depth of curve. At insertion stop point, mark vac tube for drilling. Measure swing distance of re-hung muffler, and cut vac tube at 1/16 inch less than that from the drill measure. Drill two holes for chair bolts. Insert chair bolts to keep vac tube from sliding into body of muffler. This restrains muffler side motion, creates a new *quieter* path, and doesn't too adversely mung up compression.
Eye minor hole in manifold, have to wait for high temp cement possession and sheet metal to patch that.
Detach muffler from front hanger, insert vac tube to curve depth in manifold outlet. Rehang muffler, inserting muffler entrance over vac tube. Clip and wind fence wire to both front muffler hanger and pipe bracket for manifold outlet, using a bend in the wire as a spring so there's *just a little* swing slack. This will fatigue and need redone at least once a year. Probably nabbing a new car before that.
Exhaust system now fixed, if louder than normal.
Usual Materials: High temp paint to stop rust.
Unusual Materials: Chair bolts, fencing, vacuum extension from a 1940s electrolux.
Tools: Wire cutters, vice grips.
Procedure: Jack car, examine muffler hangers for stability. Measure diameter of exhaust from muffler intake and muffler entry. Search house for some sort of metal tube to splice in. Find 1940s electrolux vac piece with no actual vac anywhere to be found. Get under car, slide into pipe from manifold to depth of curve. At insertion stop point, mark vac tube for drilling. Measure swing distance of re-hung muffler, and cut vac tube at 1/16 inch less than that from the drill measure. Drill two holes for chair bolts. Insert chair bolts to keep vac tube from sliding into body of muffler. This restrains muffler side motion, creates a new *quieter* path, and doesn't too adversely mung up compression.
Eye minor hole in manifold, have to wait for high temp cement possession and sheet metal to patch that.
Detach muffler from front hanger, insert vac tube to curve depth in manifold outlet. Rehang muffler, inserting muffler entrance over vac tube. Clip and wind fence wire to both front muffler hanger and pipe bracket for manifold outlet, using a bend in the wire as a spring so there's *just a little* swing slack. This will fatigue and need redone at least once a year. Probably nabbing a new car before that.
Exhaust system now fixed, if louder than normal.
1994 VW Jetta III with patched exhaust system
One vac tube, post cutting.
Hawk from a hand-saw
Goes through vac tube quite nicely.
Tail pipe now a touch lower.
Bugger. Happily, still not too low for clearance.
Hanger, join, chair bolts, vac tube (in between rusted sections)
Much easier than I thought it would be, much more challenging than the correct tools for the job would have been. (New pipe, new exhaust, a welder)
The fence from which the wire for hanger restraint spring was cut.
Also, some berries which would probably taste like burning.
Five points for having fixed the car enough to drive again. Thankee, sir!