Our little pickup truck failed the emissions test. The smog technician said there was no pressure at the exhaust pipe outlet. That was an indication that there was a leak in the exhaust system. Well when I finally got around to inspecting the exhaust plumbing lo and behold there was a hole in the muffler! I went down to the automotive parts store and located a product that they sell for exhaust repairs. It included a chemical paste to be applied to the area to be repaired. Since I am not too fond of using/touching chemicals; I thought what is another way to repair this hole in the muffler? Then I realized that the hole could be plugged. I searched through my hardware bucket and found a nice metal plug. With a little bit of elbow grease the plug fit snugly into the muffler. Furthermore I had some non- toxic polymer clay that I had used in another project. I cleaned the area around the plug and applied this clay to complete this repair. Needless to say, our truck passed the emissions test after this repair!

Image 1 is showing the completed repair.

Image 2 is showing the hole in the muffler.

Image 3 is showing a steel plug/bolt that is compatible with the size of the hole in the muffler. Any short stubby threaded bolt will work.

Image 4 is showing the plug threaded into the muffler.

Image 5 is displaying the polymer clay used to seal around the plug.

End notes:

Small holes in high temperature environments can be plugged and sealed with clay. Clay tiles were used on the space shuttle and withstood re-entry temperatures!

I hope this proof of concept helps someone else repair their muffler or exhaust component.

<p>Nice and simple! I love automotive tricks like this. Thanks for posting this!</p>
Thank you! I love being able to share my ideas!

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