exhaust leak and 12 year old rust, help!

[Mystic511]

The gasket connecting the catback pipe to the axle back section of the muffler is completely corroded on my tsi awd. The problem is, the bolts on the flange are completely rusted and if i didn't know there were bolts there, i wouldn't ever recognize them as bolts.

What do I do? I have to do inspection soon, and i'm not ready to do an aftermarket exhaust yet. Don't have the money to spend really and I kind of wanted to enjoy having a quiet stock car for a while.

I'm worried that if i attempt to take apart the flange, the whole thing will just crumble and I won't be able to put my muffler back on. Anyone have a solution? Or maybe an idea at a temporary fix?

 

[Krazysmit]

When I was swapping my stock exhaust out of my car it was so rusty I pulled a little too hard on the bolt and the whole thing snapped in half, my muffler going one way and the cat-back the other. Best solution is try to find stock one in junkyard, or DSM Trader. I'm not sure about any kind of repairs to insanely rusty pipes. If turbo-cat is ok, it shouldn't be too hard to find a cat-back used in better shape. Go used all the way!

 

[Tallen]

They sell this exhaust wrap stuff. It basically follows the same concept as a mummy. Put the paste on the strip then put the strip over the exhaust hole. Start the car and let the patch warm up to harden it. Check the local parts store. (muffer mend?)

 

[jbillakdsm]

They do make a squeeze tube temp fix for exhaust systems. I think it is actually called muffler mend like Tallen said. If you are worried about the sections right before and after the flange breaking apart as well, find a soup can or canned vegetables that have the same diameter as your exhaust. Cut the top and bottom off and then cut the can length-wise. Spread till it fits over, put some muffler mend on the inside and squeexe it bakc over your exhaust, use a clamp if necessary. I did this on a buddies Rodeo and it passed emissions and inspection.

 

[Mystic511]

The exhaust leak is coming from the flange.. you think I can just slop some of that muffler mend into the flange and hope it seals it?

I know it's a ghetto fix, but I just need something to get me through inspection.

 

[Tallen]

Oh yea, it'll work!

 

[Mystic511]

Ok, i got some of the mending stuff and slobbered it all over the flange. Hopefully it will seal properly. I'll post and let you guys know if it's a viable solution or not.

I didn't get the muffler mend stuff (it's called muffler weld) because it came in a can instead of a squeeze tube. I figure the one in the squeeze tube will work just as well. I forgot the name already so when I get home later I'll post it.