Original muffler, can this be saved Options

[Ron914]

This is the original muffler from my car . I was wondering if it can be saved/fixed.
Not sure if this will be required to pass smog on my 1976 as it is part of the original equipment needed to pass as a 49 state car in California . I currently have the repaired Bursch I got from Franz @drem914 installed on my car but not sure if this will be a problem when I go for my smog test ?
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[Jack Standz]

Yes. But, welding on thin rusty metal is not easy. Maybe better to cut out the rusty part and weld in new metal.

Quick fix is this stuff:

https://www.amazon.com/Permatex-80333-Muffl...B000BKEBOU?th=1

[Ron914]

Yes. But, welding on thin rusty metal is not easy. Maybe better to cut out the rusty part and weld in new metal.

Quick fix is this stuff:

https://www.amazon.com/Permatex-80333-Muffl...B000BKEBOU?th=1

That's an option I did not think about . I was thinking of using a grinder with a cutoff wheel and cutting away the bad metal then have the end cap re-welded back on . Not sure if that would be a good idea but seems like it would work .

[burton73]

Ron,
You should go for your smog with the cat on. Looks like the top picture is no cat. I would weld a patch on the cat or wire brush the cat and put the muffler patch on. They are going to be looking for a cat on your 76 car. After you pass, put the top picture muffler that I belive has no cat. You are going to be dealing with this every 3 years. I had a 76 and it passed smog but still was a pain in the butt.

Good luck my friend,
Best Bob B

I know that you are ready for your car to pass.
(IMG:style_emoticons/default/driving-girl.gif) (IMG:style_emoticons/default/driving-girl.gif) (IMG:style_emoticons/default/driving-girl.gif) (IMG:style_emoticons/default/driving-girl.gif) (IMG:style_emoticons/default/driving-girl.gif) (IMG:style_emoticons/default/driving-girl.gif)

[Ron914]

Ron,
You should go for your smog with the cat on. Looks like the top picture is no cat. I would weld a patch on the cat or wire brush the cat and put the muffler patch on. They are going to be looking for a cat on your 76 car. After you pass, put the top picture muffler that I belive has no cat. You are going to be dealing with this every 3 years. I had a 76 and it passed smog but still was a pain in the butt.

Good luck my friend,
Best Bob B

I know that you are ready for your car to pass.
(IMG:style_emoticons/default/driving-girl.gif) (IMG:style_emoticons/default/driving-girl.gif) (IMG:style_emoticons/default/driving-girl.gif) (IMG:style_emoticons/default/driving-girl.gif) (IMG:style_emoticons/default/driving-girl.gif) (IMG:style_emoticons/default/driving-girl.gif)

Hi Bob , I am hoping I won't have to do that . I was told to pass the car only needs to have all the original equipment that it was sold with when tested , my car never had a cat as shown by the original muffler that was on it .
I had the Bursch that's on it now repaired by Tiger Vasquez (thanks for the recommendation) .
one of my next stops is to see him about repairing this muffler and getting some bungs welded in for my AFR meter . I want to see where I am at before going to a smog shop and make any adjustments . Keep your fingers crossed for me .
door jamb information on my car .

[sixnotfour]

California is special...

[JeffBowlsby]

I have a similar question about an original muffler with a small hole in it, about 1/4 in diameter. Believing the internal corrosion is a greater area than that hole, and wanting to both keep the muff and do a good job, I wonder if a good welder can not just weld on a surface patch, but actually cut in a butt welded patch and grind it down flush to look and function like no damage ever occurred. Anyone with experience with this technique, any drawbacks?

Will a muffler shop do this or does it require a more skilled welder?

[Ron914]

California is special...

I have one other card up my sleeve when I go for my test . My car has BAR reports showing it has been passing smog in California since it first came here in 1985 .

[Jack Standz]

I have a similar question about an original muffler with a small hole in it, about 1/4 in diameter. Believing the internal corrosion is a greater area than that hole, and wanting to both keep the muff and do a good job, I wonder if a good welder can not just weld on a surface patch, but actually cut in a butt welded patch and grind it down flush to look and function like no damage ever occurred. Anyone with experience with this technique, any drawbacks?

Will a muffler shop do this or does it require a more skilled welder?

Have repaired/welded a stock 2 liter muffler with a rust hole (like the one in the photo). Yes, it wasn't so easy. But, a good welder with the right settings and patience should be able to fix it. But, if the rust is extensive, the bandaid may have limited life.

The problem is the metal is thin and you can easily have blowouts. Used a mig welder, but next time might try TIG.

[wonkipop]

California is special...

I have one other card up my sleeve when I go for my test . My car has BAR reports showing it has been passing smog in California since it first came here in 1985 .

brilliant.

(IMG:style_emoticons/default/biggrin.gif) (IMG:style_emoticons/default/biggrin.gif) (IMG:style_emoticons/default/biggrin.gif) (IMG:style_emoticons/default/biggrin.gif)
and i guess the door jamb sticker sticks it up em too.

i imagine you are only stuffed if you have an original california cert car still in california?
and that you must have been able as a resident of the rest of the real united states, been able to take your car to california with you at some stage, and live there with it, in freedom as you followed economic opportunity etc over the last half century.

or am i wrong as an ignorant aussie (but always mystified by the specialness of california). surely if the car went there in 85 and has never left since it must only have to meet the emissions standards of the state it was originally sold in, even if the californians want to test it every other year?

i say this as a person who still remembers taking a smog test in chicago and the relief i felt in passing it and the greater relief of returning here.............where there are no smog tests. (IMG:style_emoticons/default/beerchug.gif)

weld up the muffler and go for it, you are only doing it for the smog test.......right?
and if its rusted on the outside, then sure as shite its baffles etc on the inside are gone anyway. its just a cosmetic job for the smog test? (IMG:style_emoticons/default/beerchug.gif)

[JeffBowlsby]

^^^this.

[Lockwodo]

I've seen a lot of California smog tests over the years and nary a comment ever about muffler condition. For older cars where a tailpipe emission test is required, as long as the tech can find a tailpipe to stick the probe into, he could care less about checking out the muffler.

[Ron914]

I have a similar question about an original muffler with a small hole in it, about 1/4 in diameter. Believing the internal corrosion is a greater area than that hole, and wanting to both keep the muff and do a good job, I wonder if a good welder can not just weld on a surface patch, but actually cut in a butt welded patch and grind it down flush to look and function like no damage ever occurred. Anyone with experience with this technique, any drawbacks?

Will a muffler shop do this or does it require a more skilled welder?

Have repaired/welded a stock 2 liter muffler with a rust hole (like the one in the photo). Yes, it wasn't so easy. But, a good welder with the right settings and patience should be able to fix it. But, if the rust is extensive, the bandaid may have limited life.

The problem is the metal is thin and you can easily have blowouts. Used a mig welder, but next time might try TIG.

I would have never guessed this was a used old muffler , looks like new . I currently have a Bursch on it now with a new muffler welded on , I only wanted to see if the original could be or worth fixing . Your muffler look great . Appreciate the response here .

[Jack Standz]

I have a similar question about an original muffler with a small hole in it, about 1/4 in diameter. Believing the internal corrosion is a greater area than that hole, and wanting to both keep the muff and do a good job, I wonder if a good welder can not just weld on a surface patch, but actually cut in a butt welded patch and grind it down flush to look and function like no damage ever occurred. Anyone with experience with this technique, any drawbacks?

Will a muffler shop do this or does it require a more skilled welder?

Have repaired/welded a stock 2 liter muffler with a rust hole (like the one in the photo). Yes, it wasn't so easy. But, a good welder with the right settings and patience should be able to fix it. But, if the rust is extensive, the bandaid may have limited life.

The problem is the metal is thin and you can easily have blowouts. Used a mig welder, but next time might try TIG.

I would have never guessed this was a used old muffler , looks like new . I currently have a Bursch on it now with a new muffler welded on , I only wanted to see if the original could be or worth fixing . Your muffler look great . Appreciate the response here .

That is just a sample/stock photo because I don't have a very good photo of the one I repaired. But, repairing the old muffler saved $$ that can go into other parts of the restoration.

Here is a poor photo of the one with the weld repair. It's not currently in a car and time will tell how long the repaired pinholes will last.