The muffler on my '99 Forester is rapidly deteriorating- Rusting around where the tail pipe meets it. The car is very loud and I don't want to be pulled over in some of the uppity towns we drive through. Is there a tape patch for this problem? I understand it's only temporary fix, but is it worth a try? The car seems to have more power this way, or am I imagining it do to the noise.

Thanks for any pointers.

You could try one of those mesh/putty repairs. However, you would need to grind around that area pretty well so that the putty had some place to stick to.

 

Something like this perhaps: http://www.autozone.com/autozone/catalog/accessories/accProductDetails.jsp?itemIdentifier=710675_0_0_&skuDescription=VersaChem+/+6.5oz.mufflerweld&brandName=VersaChem&displayName=6.5oz.mufflerweld&skuDisplayName=VersaChem&categoryNValue=10099999&navValue=100436&categoryDisplayName=6.5oz.mufflerweld&parentId=00-10&itemId=436-10&store=1883&productId=710675

 

They don't last that long though.

Midas will weld it up for you [assuming the break is not right at the muffler] for about $70. The weld will last at least 2 years.

Midas will weld it up for you [assuming the break is not right at the muffler] for about $70. The weld will last at least 2 years.

You can't really weld rust and I don't know if they'd have pieces of patch metal lying around.

I got this one exhaust patch goop somewhere, I think it was at napa, that seems to work pretty good on smaller leaks. It has sodium silicate and a bunch of warnings all over it. But for a bigger leak some kind of wrap would be needed as well.

 

Fortunately the exhaust isn't going to be quite as hot way back that way as it would be further upstream in the exhaust system. So in the way back I have had good luck with JB Weld or the similar epoxy products bridging even 1/2" holes or so if you wait for it to harden a little bit before smoping it on. Or you can get some wire mesh mixed in there like hardware cloth or something to help support it while it hardens.

You might be noticing more power with a leaky exhaust, I had noticed that too on '00obw when the donut was gone out. Because then there is less restriction on the exhaust gases which means the engine spends less power pumping out the exhaust, which leaves that power for driving the transmission vroom. You could put in those side exhaust cutouts like the muscle cars. Then when they want to do a fast take off the open the cutouts, then once you're cruising they close them again so it's quiet.

I definitely recommend welding. The glues will not last. Midas and others weld a 6" steel cover over the leaking area so the "rusted" area itself isn't welded.

You might try cleaning the rusted off as best you can with a wire brush, then applying JB Weld, and let it harden up over night. It will work for a while.