Introduction: Muffler Splint

About: Building design/consulting in Vancouver, WA. Resource based problem solver... in other words, I always take a minute to look in construction dumpsters :) ---the way some have to workout everyday... i have to …

How to secure a loss muffler with an aluminum can.

It's Simple. In two steps you're car will go from scaring children to humming like an angel.

Follow these steps or do a better job by using multiple cans to make a more sturdy splint. I'm three weeks in and the splint is holding up beautifully. Here's how!

Step 1: Tools & Materials

Thanks to the sponsor of a local design event. A month ago Green Sheep Water sponsored a Creative Mornings event at Leo Burnett in Chicago. Thanks to all involved especially the team who has organized for years in Chicago and around the globe.



  • Aluminum can - any will do. Use multiple to build up more material and a stronger splint
  • Hose clamps - 3-5"

Step 2: Can Prep

Snips aren't even necessary. If you're handy with a knife you can easily prep the can. Take caution when working with sharp edges.

The can is the exact diameter of the pipe so it's easy to match. Additional layers help build up a more substantial support.

Step 3: Pipe Prep

The pipe will have rusted and swelled at the break. Clean off the rust using a wire brush.

The photo shows my poor prep work that was accomplished with a pliers. If I need to replace the splint I'll use a wire brush.

Step 4: Secure the Splint

Apply a hose clamp on each side of the break. I held back on securing as tightly as possible because I was concerned my poorly prepped surface would tear the can. The can is most durable as a solid piece and if torn will become significantly less dependable.

Will comment over the coming weeks if the single can breaks and I need to replace it with multiple layers.

Good luck and thanks again to the folks at Creative Mornings and Green Sheep!


--if you want to make things easier you can always buy a muffler coupler :)