this is what I get for running over too many snowbanks

Mighty Subie

Mighty Subie

New member
( I posted this on STM this spring but everyone was over here by that point so I figured I would repost it now)

Last winter, the driveway for the house I worked at wasn't cleared yet after a storm. So I did what any reasonable subaru owner with snow tires does... I cleared a path through the snowbank with my car. Screw shoveling! Well I noticed that my car became louder. I figured that the gasket up next to my cat probably had broken again since it seemed rather cheep when I had replaced it last. Well I got it home and backed the car up on my ramps and discovered that the gasket was fine, but my muffler was not. Here's some pics.

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Oh, I forgot to mention that I have a full stainless exhaust. The damn muffler wasn't welded properly from the factory. The end that didn't come apart wasn't even held together that well. I never even gave it a thought before but here's the end that had stayed together:

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So I cleaned it up and welded it back together. But the rod I was using was old and the flux kept breaking off and falling ahead of my puddle and then wouldn't flow right creating voids of slag. I guess it's not a void if it's full of slag.. but you get the point. Here's the result with my home made gasket. Yes i cut it open, I was just holding it for reference.

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M&A will be fixing the same thing on a rs today cheap ars magnaflows and is that your new exhaust gasket at the end
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well that was/is my exhaust gasket. I didn't have any place where I could go buy a new one when I was fixing mine so I had to make one. You put enough layers together and it works great. Just make sure you crank your bolt tight. I did that in Jan or Feb and it's still holding strong without leaking. Maybe I'll let it go a year before I replace it with a real one. Maybe I'll just wait till I NEED to!

But if anyone else is experiencing an issue like this, let me know. I'll weld it up for them. My welder is an hour north of Augusta though so I can't just do it up real quick, I'd need to take a good part of the day to do it.

 
Well did it sound good before you welded it?
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Sounded awesome, just a little too loud for my taste of a daily driver. It's already loud enough. Could use some dynamat in there.

that is clean weld. Mig is a bumpy ride but you sure know you did something. no rolled seam on this muffler?
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Nope, no rolled seams. The seams actually popped apart because the ends just slide over the body of the muffler. My welds were actually with my stick welder. I didn't have any stainless wire for my mig.

 
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