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The old clunker's exhaust was blowing a bit, so I sealed it.

Then it fell off. It had rusted right through between the catalytic converter and the silencer.

"You know what you're going to have to do, don't you?", said Kitewife.

"Fix it?"

"No, write an Instructable!"

[Some of my more recent projects are now here.]

Step 1: Materials and tools.

This is a fairly simple job (it only took me half an hour), but you do need some specialist materials:

  • Wheel ramps or axle stands. Do NOT attempt any jobs underneath a car supported just by a jack. People die like that.
  • Eye protection (unless you enjoy rust, dirt and toxic chemicals being dropped in your eyes...?)
  • Metal snips.
  • Jubilee clips.
  • Screwdriver (flat-head, to match the jubilee clips).
  • Assorted pliers, spanners and thumpy things.
  • Exhaust repair paste (available from any car spares store).
  • An empty tin can.

You should also wear appropriate clothing - spare a thought for whoever does the laundry in your home, and be aware that you could quite easily get un-removable gloop on your clothes. An old hat might help as well.

<p>I am going to try to remain positive here but it's going to be hard. Yes this will help cut down on the noise that your car is making, it is the worst example of home car repair I have see in a while. Kiteman kudos for trying to fix it and I know it is not ment for a long term fix but see how many people are wanting to do this to pass smog tests and inspections. Not to mention this could cause more damage to the car or cars behind it if something broke and came off the car like the tail pipe. I know the point of all of this is to do a low cost repair but this is even pushing that. A better fix would have been to borrow a hack saw and cut off the flange and for about $10 bucks buy 2 exhaust clamps and a double flared patch pipe from the auto parts store and installed that and it would last for a couple of years and be a lot safer and pass inspection. Again this would be a temp fix for the side of the road but I would not encourage anyone to do this is they have time to either do it right or at least get a few basic parts. Hope I was not to harsh.</p>
Kiteman, im new to car repair and was wondering if you felt that this method combined with Exhaust Bandage would work as a temporary fix reconnecting the exhaust pipe to the back end of cat converter? (Apologies if discription isnt the best)
<p>Without knowing details, my best answer can only be &quot;probably&quot;, with a firm reminder that free advice from the internet can sometimes be worth less than you paid for it...</p><p>However, it was me, and I was trying to keep my car on the road until I could afford a proper fix, I'd do it.</p>
92 chevy cavalier rust damage caused seperation, just trying to get like 3-4 temp fix mainly to make it more quiet till payday. Going to give it a shot. Thank you for the information you have provided bub!
<p>It's what we're here for, thanks for the feedback!</p>
Just figured id post a follow up. Can and clamp rig worked out better than i though it could! Car is back to being quiet again and not sounding like a derby car.
<p>Awesome!</p>
#1 no your car will not pass emissions they use mirrors and look for modifications to exhaust such as missing cats.. #2 it works for a few weeks at most it heats up becomes weak and falls apart.<br>This is ghetto at best
<p>#1 It does nothing to your emissions - it's fixing a break in a pipe, not replacing the catalytic converter.</p><p>#2 It lasted until I eventually sold the car for parts - several months.</p>
<p>Awesome, article and a great way to fix the exhaust. HUGE thank you for taking the time to write, take photos and all that stuff :)</p>
<p>And thank <em>you</em> for your kind words.</p>
<p>Thank you, Sir! Outstanding Instructable.</p>
<p>Thank you!</p>
<p>Burned beans!! LOL</p>
i need to know if I do this will my truck pass smog
That doesnt depend on a leak so much as what your engine is doing... if your burning oil or have bad sensors or a hollowed out cat chances are you wont pass.
<p>Oh, sorry, misunderstood.</p><p>I have no idea. All this does is fix a hole in the exhaust - if your truck failed bacause of holes, then, maybe, but I don't know the rules/laws in your area.</p>
I made my first instrucable based on yours <br>http://m.instructables.com/id/snapped-exhaust-repair/<br><br>Thank you for the guide
<p>Cool - your version came out neater than mine!</p>
after doing this will my truck pass smog
<p>Cool.</p>
<p>How would you repair a similar hole that is in the elbow of the exhaust pipe?</p>
<p>Use a putty, its like dough so you roll it in a ball to activate, then can squish it an form it around the elbow, you can work it into creases an it will not run or drip. As long as you keep the two parts from moving, it will seal nicely around the piece. If you use thermal weld it will get stronger with heat </p>
<p>I'd be tempted to use a round headed hammer to shape a piece of can into a curve that fits.</p>
<p>Use flex pipe, usually 1.5 foot long. Could cut it much shorter. Lasts <br>ax. one year. Worth it. A section of my exhaust is flex pipe until I <br> pop for a $175 new part.<br>Add to the road kit: two clamps, flex pipe or whatever.<br>Note that cutting an exhaust pipe on the car can be a huge PIA unless its hanging down already. Note that a car sending unburned gas to the CAT can lead to very high temperatures, bad news if touched accidentally.</p>
<p>hi kiteman, <br>i am ravi from india saw your method and got an idea to fix exhaust pipe crack in my motorcycle, took a deo can cut it and wrapped around the pipe and used hose clips. thanks for the instructable</p>
<p>Cool!</p>
<p>i also used silicon sealant to keep away the heat from deo can. </p>
<p>I fixed my exhaust system (on a 2000 civic) when plagued with the same problem depicted here. My fix stemmed from this instructable though I used several different components for the fix. <br><br>Rather than using a tin can I used a piece of metal piping, roughly 4 inches long. Rather than jubilee clips I used metal wire. Jubilee clips were not need because bolts were present that held the joint, and the part in which the bold clamped to was what had snapped. I would suggest only one jubilee clip to be used (around the pipe), and metal wire replacing the jubilee clip that is not around the pipe. <br><br>I also substituted the repair paste with high heat JB weld (<a href="http://www.jbweld.com/product/j-b-highheat/" rel="nofollow">http://www.jbweld.com/product/j-b-highheat/</a>). <br><br>I don't have a picture of the fix yet, though should in the next few days to attach as well :)</p>
NEVER EVER trust a ramp to hold your automobile up! Jack stands, blocks, old tire rims. <br>From me 40+ years as a mechanic and from CPSD, DOT and other places.
Ramps are fine if they have, as these, an area designed to prevent the wheels rolling off and you can leave the handbrake on. <br> <br>I may not have quite your decades of experience, the only people I know of hurt working under a car were using jacks. The professional auto mechanic I borrowed the ramps from knew of nobody hurt by a car rolling off a ramp. <br> <br>However, safety is the responsibility of the individual doing the work, and few people are hurt by too many safety precautions. <br>
Bravo! A repair an unemployed schoolboy could appreciate. A repair could have been negotiated by a bored welder with nothing to do for 20 minutes for $25.00 possibly. Or you could have applied the $25.00 to a 115 volt wire feed welding machine which typically can go on sale for $99.00. Factor in a $45.00 auto darkening helmet, and a $21.00 2lb. spool of .030 flux core steel wire, and you would be a hero to your wife with all the little repairs this would enable you to accomplish. BTW the welder I described is one of the easiest to master, runs on household 20 amp breaker, and you will kick yourself for not buying one sooner. 18 gauge mild steel up to 3/32' inch with 2 heat settings.Really opens up the world to creating quality:Instructables, instead of glue and nuts, bolts and clamps.
Small problem - UK homes run on 13A. <br> <br>The point of the project was to fix it <em>without</em> a welder.
I understand the premise of the project. I made a simiar repair when I was 17 years old. It''s a get by till you make a real repair. BTW your siganature tag states &quot;happiness is a shed full of power tools.&quot; Perhaps wiring a seperate breaker to supply more than 13 amps. That will barely run a shop vacum.
Here's the mix up. UK 240 volts at 13 amps ~= US 110 volts at 30 amps.
They're <em>hand</em> power tools - nothing larger than a drill or a small scroll saw.
i live in the same situation but i still have a welder i run it of my dads petrol generator ( he is a home construction contractor )
I am not trying to be insulting or condescending. If I have than I apologize. All I was saying is that besides skill and Intelligence of with I believe that you possess both. More advanced equipment (which is available to the average person) if they acquire slowly, opens the door to so much more. Many inventions in the UK as well as America started in sheds.=)
Great Instructable: <br>Jubilee clips is also called hose clamps. I am in Canada. <br>Jubilee clip was a common brand in the UK and has become the way to describe the product; much like 'Hoover' for vacuum cleaners.
you could have just cut off the flange, clean the area, and put an adapter over it and use muffler clamps. $10 at autozone.
...plus the cost of the tools to do the cutting ;-) (I did say it was a bodge-job. I don't even have the car any more, I sold it for spares.)
I have the same problem on my car. I'm gonna try your solution tomorrow, but I'm gonna cut the flange off of the muffler and put a tin can inside and OUTSIDE of the tail pipe (for longevity's sake...). It's too bad the tail pipe couldn't have corroded in a more convenient spot... Oh well, here goes nothing!
Take photos, write your own version - this one is over four years old now.
I salute your &quot;Captain Obvious' solution.
Well done! I like the use of a tin can to save a few bucks! I also like the idea of simply cutting off the flange of the muffler. This way, you can clamp the tin can on the outside and don't need to mess around with all the putty. Plus, this way would probably last longer...
Thanks! <br>

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Bio: The answer is "lasers", now, what was the question? If you need help, feel free to contact me. Project previews on Tumblr & Twitter: @KitemanX
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