[PatrickB]

Hey guys, my '87 TRX 350 muffler has a few small holes from rust on the underside. I originally took a wire wheel to it, removed all old paint and rust, used high temp rated JB weld and repainted the muffler with high temp paint. That was several months ago....now a couple of the spots that I had repaired with the JB weld are leaking again.

Any other ideas other than spot welding or welding a small metal plate over the holes to fix it?

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[Macarena Man]

Try the J-B Weld again . . .
Cut a nice rectangular patch . . . the length of the muffler.
Swab holes and edges with J-B . . . with 3 or more large, good quality hose clamps (screw type) fasten the patch around the bottom of the muffler.
Did this on my 350 years ago, was still good and quiet when I sold it.
Make it look good, no one will even notice !

 

[PatrickB]

I may give that a try....I know someone who welds so may see about that first. It's amazing how these old mufflers are so prone to rust, could be the climate down here.

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[Jeepwm69]

Following. I've got a couple of 350 Foreman mufflers with a dime sized hole or two. I hate to toss them, but figured they were too thin to weld.

 

[ATC4ever]

I used a cheap 110v MIG till it got too thin in one area, then i used a cheap set of MAPP/Oxy torch with a brazing rod. Pipe held up for another couple of years till it was sold.

 

[PatrickB]

Awesome thanks for the replies...I saw this stuff at an auto parts store, wonder if it would hold up on one of these mufflers.

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[GirlsRideToo]

About 5 years ago Hubby used product called Fiberfix Heat Wrap to repair his Kawasaki Mule muffler. It's still holding strong! You must follow the directions exactly as written. It might not give you the look you want and you would have to take the shields off in order to wrap it around the muffler. Just a thought.
Product is available on Amazon.

 

[PatrickB]

Here are some pics of the holes in my muffler that I am trying to repair.

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[ATC4ever]

Could always braze a piece of tin over it.

 

[Jeepwm69]

Here are some pics of the holes in my muffler that I am trying to repair.

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That's about what I'm dealing with as well.

 

[wheelsquad]

Thin piece of stainless sheet metal, then fiberfix heat wrap over that.