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rusted tail pipe at weld point fix for a 94 caprice

86 views 4 replies 3 participants last post by  sherlock9c1  
#1 · (Edited)
I'm making no claims to it being fancy but it was about 15 dollars in material.

I couldn't figure out an exact measurement because of the rust and previous owner told me the muffler had been replaced in the past ten years so no idea what original specs or design were at all.

So I asked the autozone cashier if I could take a handful of adapters out to my car.

The 2 1/2 inch inside diameter muffler side to a 2 1/4 inch outside diameter on the tail pipe fit.

I don't know how to weld and didn't want to pay for welding. I also didn't want to use adhesive or exhaust putty? because it's so final. So, decided on saddle clamps.

I'm not sure, but from what I could gather...unless they have the "relief slots" (I think that's what they're called) on the ends of the adapter then it isn't designed to be clamped on.

I couldn't find an adapter with those slots on the end so I took a hacksaw to each end of the adapter I did find.

metal on the pipe and muffler was still solid under the rust. so didn't actually have to sand off that much of it (or maybe it was just really sturdy rust).

went back and forth tightening each bolt a little bit at a time until I heard metal start to creak and then went a little tighter.

I do imagine the tailpipe side might find its way out of the clamp since it has the ability to move around back and forth and because of the way it's (annoyingly) angled I think only half of the bottom of the clamp got a squeeze on it.

but, so far, still good 1K later.

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#2 ·
Old school rules.
 
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#3 ·
Nice work! If you live in the rust belt, why not undercoat your car? At least use a mixture of ATF and used motor oil. Get a harbor freight spray gun and coat that undercarriage. Then drive down a dirt road. That's called a New England Undercoating, and it works surprisingly well.
 
#5 ·
One other tip - I always aim my muffler clamps sideways, so there's no chance of anything ever getting stuck on the studs if you end up running over something (or even something alive, God forbid). Always a wise idea to have as few protruding things under the car as possible.