DIY muffler resonator repair

In detail: do-it-yourself repair of a muffler resonator from a real master for the site my.housecope.com.

The exhaust system of a car performs very important functions to reduce the noise of the engine, reduce the temperature of gases escaping from the cylinders, as well as to partially eliminate the smoke and toxicity of exhaust gases.

The malfunction of the elements of such a system cannot be unnoticed. A muffler breakage is especially evident. When depressurizing, this element immediately loses the function for which it received its name.

Given this feature of the breakdown, it is necessary to restore the performance of this part as quickly as possible, otherwise increased attention on the road cannot be avoided not only from motorists moving in the stream, but also from traffic police officers.

The easiest way to remedy the situation is to install a new part, but due to various circumstances, replacing an inoperative muffler may not be possible. Fortunately, it is possible to repair the muffler with your own hands without welding and replacing.

This article will consider simple and effective ways to restore the performance of this element of the exhaust system of a car, but first it should be recalled under what circumstances such a breakdown can occur.

It is easier to prevent a disease than to treat it later. The same is true for car breakdowns.

Of course, all the nuances on the road cannot be avoided. But knowing about the dangers that threaten the elements of the exhaust system of a car, you can try to delay the occurrence of one or another malfunction with preventive measures.

If the car is used constantly, then sooner or later problems with the muffler will arise, regardless of the quality of the material from which this part is made. Located in the lower part of the car, this part is constantly exposed to the abrasive effect of sand and stones falling on its surface. And if, when the car is moving, a sufficiently large solid object turns out to be between the wheels, then the muffler can be completely destroyed from a strong impact.

Video (click to play).

Therefore, the main rule of extending the life of the unit is to drive the car carefully.

The muffler is connected to the exhaust system by means of threaded connections, so if the nuts are not tightened well enough, this part can be lost while driving. To prevent this from happening, the condition of the threaded connections of this element of the exhaust system should be monitored from time to time.

The muffler often becomes unusable from burning out the metal, but this process cannot be completely stopped. Slightly slowing down the failure of this part as a result of thermal and corrosive effects is possible only when processing the inner surface of this part using graphite impregnation.

If, despite all the preventive measures taken, the muffler burned out or its body was damaged as a result of mechanical stress, then many owners immediately become interested in the question of how to connect the muffler pipes without welding.

You can carry out such repairs at home using a special sealing compound.

Cold welding is a two-part adhesive that can be used to glue metal products. Is it possible to weld a muffler with cold welding, because this part is affected by a very high temperature of the exhaust gases.

The adhesive composition of cold welding tolerates high loads and temperatures well, therefore, when a burnout appears in the muffler, or cracks from mechanical stress, it is necessary to remove the part from the car and perform the following actions:

Clean the damaged area thoroughly. Cleaning is carried out with coarse sandpaper or using attachments for a drill or grinder.
The metal, free from rust and carbon deposits, is thoroughly degreased with a solvent.
Cold welding is applied to the damaged area. Gloves should be used to apply the plastic type of glue.
After applying the composition, it is necessary to wait about an hour, and then polish the layer of hardened glue.
After a day, the part can be installed on the car and operated without any restrictions.

The muffler must be repaired by cold welding in a warm room. Only at temperatures above +5 degrees will the two-component composition of the glue react with the metal surface.

Ceramic tape is a popular and effective remedy for muffler repair.

A small hole in the muffler is closed in the following sequence:

The metal is cleaned of rust and carbon deposits.
The ceramic tape is wetted with water.
The hole is closed by repeatedly wrapping the muffler with ceramic tape.

This method is temporary, but during the entire service life of the "bandaged" muffler, its function will not be impaired, and in case of repeated burnout, you can easily wind a new layer of ceramic tape.

In the trade network you can find special high-temperature sealants for the exhaust system of a car.Such funds in their composition have special cement or ceramic additives. Which, when exposed to high temperatures, freeze and form a layer that prevents exhaust gases from escaping from the damaged area of the vehicle's exhaust system.The process of repairing a muffler with a sealant is usually carried out in the following sequence:

The damaged area is carefully cleaned with sandpaper.

The cleaned surface is slightly moistened.

The sealant is applied in a thin layer to the damaged area of the muffler and the part is cured for 30 minutes.

The muffler is installed in place.

For 10 - 15 minutes, the car engine is started to dry the crack sealed with a sealant.

After 10 - 12 hours, the car with the repaired unit can be used.

The use of a sealant for repairs can delay the purchase of a new part for a long time.

THE CONTENT OF THE ARTICLE

It should be noted that a car muffler is a unit that is constantly exposed to aggressive environments. On the one hand, it is salt, water, snow and road stones. On the other hand, it is high temperature and substances from engine exhaust. In general, this link is struggling with two unfavorable environments, which sooner or later destroy it.

Made from durable metals, often steel or its alloys, which can withstand high temperatures. Did you know that near the catalyst, when driving fast, part of the muffler can simply glow red. It is not homogeneous, that is, it consists of several tribes, often only three.

1) These are the so-called pants, come from the engine

Often, the middle and rear parts, or rather their resonators (where the sound is muffled), suffer the most. There water collects and begins to oxidize the walls, then rust - that's why the muffler burns out.

There are two solutions to the issue, this is actually a replacement (preferably with an original, or a spare part close to the original), or try to repair this failed link. Usually it is simply removed and welded, previously they also used "cold welding", but its use is limited in time, after a thousand, and maybe several hundred kilometers, the sound will again appear.

In general, if they decide to repair it with their own hands, then it is advisable to weld the hole, then under normal circumstances, this part of the muffler passes several tens of thousands of kilometers.

If you nevertheless decide to repair, for example, there is no money for a new one, then follow my instructions:

1) Remove the burnt-out part. The process is not difficult, except for removing the pants (the part of the muffler that connects directly to the engine), there you have to tinker a little with the mount. It is also worth looking at the bolts, from time to time they can stick a lot, so it is advisable to use silicone lubricants that will help in dismantling.

2) After removal, we determine the essence of the problem, it may be a burned-out hole in the resonator! The pipes themselves, as a rule, rarely burn out. You also need to decide whether it is worth repairing this muffler link, often the walls that remain on the sides are also already thin, and if you weld on them, they will be the weak link.

3) It also happens that there are no holes on the surface, but the muffler still roars. Most likely, you replaced it with a similar one that fits your car, but made in a homemade way, the resonator is not correctly located in it. Repair here will be complicated, because you need to open the upper part, cut it off with a grinder, and then remake the resonator! BUT - you need to know how to position it correctly, which is also not unimportant, otherwise all the repair work will come to naught.

4) We return to the burned-out holes. Of course, many put them on cold welding, but as I wrote above, this is not for long, such repairs should be temporary, in order, say, to get to the desired destination. Some cover the hole with fiberglass using epoxy resin, if you properly prepare the place and apply according to the instructions, then such a repair can last a long time. As practice shows, several thousand, and maybe tens of thousands of kilometers.The big plus of such a repair is that you can do everything yourself. We watch a small video - instruction without welding.

5) We clean the places for welding, it is imperative that the contact is as strong as possible. Then a sheet of steel is taken and welded over the holes, thus, we restore the tightness of the resonator or pipe.

As you can see, the muffler can be repaired in various ways. Some are actually do-it-yourself - cold welding, fiberglass + epoxy. They are sold in almost every construction supermarket. Also, repairs can be more serious - welding, thus, you can extend the life of the unit for many more kilometers.

Repair video by welding.

That's all, before throwing out this part, see if it is possible to restore it. That's all, read our AUTOBLOG.

The exhaust system is a rather complex design, which includes several components. The most voluminous and creating the greatest number of problems, as practice shows, is the muffler. The malfunction of this element of the exhaust system is always heard from afar, and in the most literal sense: the muffler got its name for a reason.

The resulting malfunctions of the exhaust system are quite natural: each structural element is subjected to severe loads, which sooner or later lead to the manifestation of a malfunction. The muffler is no exception - on the contrary, it absorbs all the exhaust gases from the engine.

Muffler malfunctions can be of several types:

mechanical damage (obtained, for example, as a result of a strong blow);
corrosive destruction;
burnout of the muffler walls;
separation of individual structural elements.

It is necessary to understand that it is quite difficult to deliberately damage the muffler - after all, it was originally designed for high loads, and this element has corresponding resistance to damage. A muffler malfunction usually occurs for the following reasons:

mechanical impact (as a result of a strong blow or during prolonged driving on rough terrain);
exposure to exhaust gases at a sufficiently high temperature;
the influence of moisture;
the effect of corrosion due to the appearance of condensation in the internal cavities of the muffler;
sudden temperature changes and excessive vibration (as a result, a destructive effect on welded seams is produced);
the presence of factory defects.

Any of these causes can lead to muffler malfunctions, down to through holes. The damaged part will immediately make itself felt with a characteristic roar, so you will have to troubleshoot in the very near future.

If the problem was only in the creepy sound, then some time with the repair could wait, but a damaged muffler significantly reduces the efficiency of the engine and increases fuel consumption... That is why a good owner will try to fix the problem immediately after its detection, without waiting for the accompanying negative effects to appear.

With some skill, you can independently carry out work to eliminate problems in the muffler quickly enough if you follow a clear sequence of actions. The repair can be conditionally divided into several stages:

Dismantling the muffler.
Visual inspection and identification of the problem.
Directly repair work.
Re-assembly of the muffler.

There should not be any complications during the work, and the elimination of problems is carried out in one of the ways described below.

Recently, the method of cold welding has become increasingly popular, which makes it possible to quickly and efficiently patch any hole. Cold welding is a versatile compound that cures very quickly and has excellent resistance to oil, gasoline and other corrosive substances.

Cold welding comes in two forms:

Liquid. To create a high-quality patch, a liquid mixture is used: it becomes a shell and fastening material for reinforcing elements. The result is a reliable connection to the part.
Plastic. Such a composition, in addition to the high quality of the connection, is distinguished by excellent adhesion, which allows repairs to be carried out on poorly prepared surfaces.

For a high-quality repair of a muffler using cold welding, the following operation algorithm must be observed:

First, the damaged area is sanded to create a flat surface on which it will be easier for the material to anchor.
Further, the cleaned area must be degreased. Gasoline or alcohol is well suited for these purposes.
After preparing the site, you need to take the required amount of adhesive and bring it into working condition according to the attached instructions.
The finished mixture is applied to the damaged area and leveled. The work must be done as quickly as possible: the sealants begin to dry out within a few minutes after application.
The final stage is drying. The finished part must be left for a while to allow the glue to dry completely.

When it comes to repairing a muffler without welding, then various options for bands and patches that can be fixed with fasteners immediately come to mind.

One of the methods for restoring the muffler's performance looks like this. For repair, a special fiberglass bandage is taken, which is applied over the damaged area. This material is designed to work in high temperature conditions, so you can forget about the problem for a while. In addition to bandages and cold welding, regular metal patches can also be used. Reliable clamps are suitable for fixing them, firmly pressing the patch to the muffler.

However, regardless of the do-it-yourself muffler used for repairing the muffler without welding, you need to understand that such a solution will be temporary. And the sealant, and the bandage, and even a patch securely fastened with clamps - all these materials can eliminate only the problem, but not its cause.

It might be interesting. How to bring light into the garage: Wiring and connection.

Failed crossover tests. Read more in our article.

The reason is the damage to the integral part, which cannot be restored to its original state even when using a welding machine. If serious burnouts or holes in the muffler are found, the best course of action would be to replace it..

Sometimes it is simply impossible to solve the problem on your own and without the use of welding. For example, if the muffler bank is damaged, it is quite possible to use all the described means to create a temporary patch, but if the exhaust pipe burns out from the muffler, then it will be almost impossible to fix such a malfunction with your own hands.

In addition, the need to replace or repair a muffler rarely arises spontaneously - usually there are prerequisites for this. To prevent them, you need competent prevention: the use of suitable fuel, a balanced driving regime and timely car maintenance.

Repairing the muffler without welding is quite possible and can be done by hand without any problems. There are several ways to fix the problem, and they are not expensive or difficult to learn. At the same time, it is important to understand that any repair will only delay the inevitable replacement of the muffler - no patches will be able to return it to its original performance.Almost a month ago (08/13/2015) I had a joyful event that hit me - 35 years old. My mom's question is "what to give you for jam day :)?"
- "Um ... maybe a Porsche 944th))))"
- "Mine for him myself, let's get something cheaper))"
- "Okay, I'll think about it."Meanwhile, the sound of the exhaust gradually became louder and louder, but not where it should be ... There was no way to get to the welders, then there was no time, then they were not there ...And having collected a certain amount of dough, my own and my relatives, I wandered into the store in search of the necessary device.Required attributes to it:And so I become a professional welder! no, no, until this moment, I have never studied to be a welder and never cooked anything (except for food :)). But I saw how others do it and it seemed to me that it was not so difficult ... To begin with, I decided to try it on the garage door, to close up the hole.It didn't work out badly for the first time. So we will torment the muffler. We are going to the dacha, and not to the garage like all normal people)) Using a simple device, we raise the car.To remove the muffler, you will need overalls, goggles (so that debris does not fall into your eyes) a cardboard box, a 13 key, two 13 heads, an extension cord, a crank, a ratchet and rag gloves.

We crawl under the car and unscrew the flange (a couple of bolts, head 13 with a ratchet). We crawl out and remove the rear wheel, then, embracing the rear axle, unscrew the second flange (two bolts with nuts, heads 13 with a ratchet or pushing a key 13). If you are too lazy to remove the wheel, you can unscrew it from below, just crawl under the car. Then, using some kind of lever (a large key or a pry bar will do), remove the muffler from the rubber bands on which it hangs so tightly.We carefully inspect for the presence of all kinds of jambs and see holes not provided by the manufacturer:We will learn how to cook adaptations along the way. We turn on the device, set the current to 73 A (at 60 A, the electrode often sticks) and start hooliganism ... An interesting flame is obtained when you look through a mask ... after a while we see a lot of excess iron instead of unnecessary holes. File in hand and "cut Shura, cut ..."I think I need to buy some more adaptations in order to cut the pieces of iron faster.Again we crawl under the car, hang the muffler on rubber bands, fasten the bolts, installing new gasket rings. We get out, start the engine, enjoy the time spent with benefit. Where I welded it will definitely not fall off! ))Only a small fraction of car enthusiasts would like to have a loud sports exhaust on their cars. The vast majority of drivers, on the other hand, are puzzled by the question of how to make a quiet muffler. Riding can be comfortable only when as little extraneous sounds as possible penetrate into the cabin. The muffler creates its own background noise, which can be significantly reduced. The effect of this cannot be overlooked.Before proceeding with the modernization of the exhaust system, you should understand the nature of the increased exhaust sound. With each working stroke of the piston, a micro-explosion occurs in the combustion chamber of the engine cylinder, which is accompanied by a significant sharp expansion of gases. Naturally, a kind of blast wave, after it has done its job and moved the piston down, rushes through the exhaust system with the opening of the exhaust valve.Thus, the nature of exhaust system noise is twofold.:

sound from the expansion of gases;

noise from vibration of elements of the exhaust system.

As you know, the main way to deal with noise is to increase the weight of the elements. The thicker the metal, the less vibration and, consequently, noise. Therefore, the exhaust manifold, which is the first to receive the hot gases from the cylinder head, is made so massive. Many motorists, who had the opportunity to compare the weight of the exhaust pipe of a domestic car and a foreign one, noted that the parts of the exhaust system of foreign cars are much heavier. That is why "our" cars are less comfortable when compared to sound and noise.Special elements are called upon to reduce the speed of gas movement in the exhaust pipe: resonators and mufflers. The first in line is the resonator. As soon as gases under pressure enter the part of the pipe with an increased volume, they immediately lose some of their energy and move further with less momentum. In the muffler labyrinth system, the exhaust gases finally lose their energy and dissipate. A real quiet muffler on a foreign car is quite heavy and has several separate bodies.Quiet muffler with your own hands, video:

Let's consider repairing a muffler with our own hands using the example of a ZAZ Tavria car.
Useful for us:

wrenches;
sandpaper;
set for cold welding;
a piece of tin;
clamp with threaded tie.

We begin to repair the muffler of the Tavria car with our own hands from the inspection pit.

First of all, we determine the place where gases break through. It's good if the hole is outside. Next, we describe how to close just such a hole.
First, we dismantle the entire assembly, for which we unscrew the fasteners.
So, the unit is in front of us. In Tavria, it is simple: there are two chambers inside, one of them with a diffuser. We clean the hole thoroughly with sandpaper. This must be done without fail, otherwise there will be no sense.
After mixing the components, apply cold welding with fingers in a glove.
We tighten this place with a clamp around.
We install the unit back.

In fact, the recommendations for many other cars also look like. After all, we specifically described these recommendations in general terms, which help to repair the muffler with our own hands, but only with cold welding.

Another thing is when the front pipe fails. Here it is unlikely that you can help with local repair of the exhaust pipe of the muffler with the help of some cunning means and with your own hands. There is only one way out - replacement. After all, these "pants" - receiving pipes - perceive the very first powerful blow of exhaust gases. The load is so great that local fittings will only help you get to the garage.

To replace "pants", for example, on a "classic" VAZ, you must have:

spanners;
penetrating lubricant.

Also read about replacing the propeller shaft cross and repairing the starter with your own hands.

Here's what to do. We start from the observation pit.

We dismantle the rear part of the muffler.
We detach the resonator.
We unscrew the clamp bolt that holds the front pipe.
We open the hood, then unscrew the nuts securing the intake pipe to the exhaust manifold.
We remove the defective part, as well as the gasket.
We install a new part together with a new gasket according to the reverse sequence.

The main thing here is not to forget to process threaded connections that cannot be loosened with a penetrating grease of the "vedashki" type. And after processing, wait a few minutes. Although it is possible that some nut will have to be carefully cut off with a "grinder", because all elements of the exhaust system work in extremely harmful conditions, so they quickly stick to it.

And now we will consider repairs on several more cars. Take Nissan, for example. If the gasket of the unit burns out, it is better to replace it. For Nissan Note, like other cars, do-it-yourself repair of the muffler gaskets does not make sense.

But repairing the exhaust pipe of the muffler with your own hands without welding is just appropriate. For this you will need:

ceramic sealant;
tin tape;
scissors for metal;
pliers with fine ends;
hammer.

Be sure to clean the leaky place. The assembly does not need to be removed from the vehicle.
Apply a generous amount of ceramic sealant with your fingers (we use gloves to protect your hands) directly on the hole.
We wrap this part of the pipe with a tin tape. We cut off the protruding ends of the tape, leaving 2 centimeters from the pipe.
Bend the remaining ends with pliers.
We knock the bend with a hammer so that the clamp obtained in this way squeezes the pipe tightly.

With the result obtained, you can travel more than one hundred kilometers.

In addition, consider repairing a muffler at a Gazelle. Let's say the resonator is broken. This element of the system uses a tube with many holes. Due to them, low frequencies are extinguished - the gas, passing through many holes, rubs against itself.

It is not difficult to repair the muffler resonator with your own hands if the outer wall is leaky. Suppose the place where the tube comes out of the resonator is burnt out. Dismantling the unit from the car is practically not required here. For our work, we take the following things:

cold welding;
sandpaper.

You need to do some simple manipulations.

We carefully clean the gap that appears with sandpaper.
We hammer it abundantly with the composition, mixing the components. We also spread a large layer on top, gloves should be on the hands.
We give the squad time to grab.
Sand lightly with sandpaper.

With such a repair of the muffler with your own hands and without welding, you can also drive a decent number of kilometers.

However, if such a muffler repair turned out to be short-lived, it is better to call in for a service. There you will definitely have major welding works, this will allow you to travel hundreds of thousands of kilometers without thinking about the release. Moreover, everything will not cost so much.

The cost of welding, together with the removal of the element and its installation back from the car service masters, is indicated in the table, relative to different large cities of the Russian Federation. Here is the table.

Many car enthusiasts do not even think that a muffler is one of the parts of a car that works in the harshest conditions. Sometimes, it is very, very difficult to repair a burnt-out muffler.

The content of the article:

Reasons for failure
Purpose of the muffler
Repair methods
How to prolong life
Video

Before proceeding with the consideration of elimination methods, we will figure out why the muffler fails, because if you know the reasons, you can prevent several problems at once.

Where there is no asphalt, most often stones flying from under the wheels of a car hit the muffler. It is heated by exhaust gases to a temperature higher than the engine itself, because it does not have a separate cooling system. Of course, during the passage through the exhaust tract, the gases cool down, but not by that much.

Another point is condensation. In the cold season, this problem is especially acute, because the muffler is cold before the engine starts, and then it gradually heats up, albeit to a low temperature. The water that condenses on the inner walls does not evaporate, and every day it becomes more and more. And only in summer, in hot weather, this phenomenon passes.