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Fun experiment: JB Weld muffler repair

BarnyardEngineering

BarnyardEngineering

Well-known Member
Location
Rochester, NY
JB Weld Steel Stick epoxy putty to be exact.

My 2002 Chevy 3500's muffler (stainless, so WTH?) rusted out along the weld seam on one side.

There is no factory replacement option for the 8.1L muffler, so to buy me some time while weighing options, I patched up the hole with a couple of JB Weld Steel Sticks.

For perspective, we patched a massive hole in a Farmall C manifold with Mighty Putty about 10 years ago. Still holding strong.

Any bets on how long it will last? Sounds like a new one now.
 
(quoted from post at 11:01:28 07/24/20) You say there is no factory replacement options. I did a quick google search and there seem to be quite a few options.
Click to expand...

They say they are the same, but they are not the same. Most of them are dual-inlet, single-outlet, or the wrong size inlets/outlets, or the wrong size muffler.

There's nothing wrong with the pipes. I just want to cut the old muffler out and weld a new one in.
 
I tried regular jdweld on an intake of a 366 chevy engine, was the crossover under the carb, didn't last a mile. And use JB a lot. Like to hear your results as I have an 8.1 in a 05, the exhaust is in good
shape though.
 
JB Weld does wonders. I don't know if the muffler will get too hot for it to hold. A Campbell's soup can cut in half bailing wired to the muffler also works. Stan
 
The kid who drove my current truck before me cut the factory muffler out and went with straight pipes out the back.

Dad said you could hear him start it up in the High school parking lot almost a mile away at their home, and that's just the 6 liter. I paid a local shop $500 to replicate the two-in-one-out stainless muffler and pipe.
 
I'm surprised the JB Weld would hold up to the heat. I tried to patch a small hole on a manifold once so I could get state inspection and it didn't last the seven miles to town get it inspected.
 
They make an actual exhaust putty that works pretty good jb
won’t hold the heat up on an exhaust manifold but it might as
far back as a muffler
 
(quoted from post at 12:34:10 07/24/20) JB Weld Steel Stick epoxy putty to be exact.

My 2002 Chevy 3500's muffler (stainless, so WTH?) rusted out along the weld seam on one side.

There is no factory replacement option for the 8.1L muffler, so to buy me some time while weighing options, I patched up the hole with a couple of JB Weld Steel Sticks.

For perspective, we patched a massive hole in a Farmall C manifold with Mighty Putty about 10 years ago. Still holding strong.

Any bets on how long it will last? Sounds like a new one now.
Click to expand...

Surprised reading this thread how many others on here have an 8.1, I looked for years before I found mine.

Anyhow back to the topic one of our boys recently purchased an 05 with the 8.1 in it and being young and male the first thing he did was put a robust sounding muffler on it.

Try talking to a few exhaust shops and you might get lucky and find one that has a like new factory take off muffler sitting on the shelf.
 
(quoted from post at 10:34:10 07/24/20) JB Weld Steel Stick epoxy putty to be exact.

My 2002 Chevy 3500's muffler (stainless, so WTH?) rusted out along the weld seam on one side.

There is no factory replacement option for the 8.1L muffler, so to buy me some time while weighing options, I patched up the hole with a couple of JB Weld Steel Sticks.

For perspective, we patched a massive hole in a Farmall C manifold with Mighty Putty about 10 years ago. Still holding strong.

Any bets on how long it will last? Sounds like a new one now.
Click to expand...

If that muffler is like the one on my 2001 with the 8.1, it is a dual inlet, dual outlet, and then the tailpipes merge into just one tailpipe. It would be very easy for a competent muffler shop to replace that single muffler with a pair of glasspacks or even some performance type mufflers that are QUIET.
 
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