Muffler blues
 

The muffler developed a leak so I took it all apart and found out the aluminum muffler box support has a crack in it too. Any ideas on fixing this?
Attachment 53321

Attachment 53322

Attachment 53323

Attachment 53324

You have a TIG welder nearby? I recall seeing a low heat ( propane ) "brazing" type repair for aluminum boats. There is also aluminum epoxy on ebay for about $15 shipped too.

My 1450 muffler cracked there too. I wire wheeled it and mig'd it, it's too dirty for tig. Use a higher heat setting and spot welds...zaap, wait a few sec move over 1/4", zaap again. It's been 1 1/2 years and no issues.

Tig will be the easiest on the muffler box. I would still be worried about recracking, may want to plate it and/or add a muffler brace. I made one for mine 2 weeks ago, but am too embarrassed to show it.

Bill

I would say mig the muffler after drilling small holes at each end of the crack and have someone tig the box or aluminum mig spool gun but TIG is best.

Well I added a muffler brace and mig'd the muffler. It came out great, best weld I ever did and the picture got deleted somehow and I didn't know it till everything was back together. I checked on having the box welded and I think I'll wait till I find a used one. This is how I fixed the box till I find one and it seems to work for now.
Attachment 53839

Attachment 53840

Attachment 53841

Attachment 53842

Attachment 53843

Attachment 53844

Nice work Keith! If it works well, I'd leave it! :beerchug:

Bcdsfcret
 

Clean the joint up with a wire wheel on a 4" grinder then braze the crack up>
Brian

+1

(and some other stuff because my message is too short)

Great job! :beerchug:

Great job! I agree, no sense in pulling it all apart if your plating fix works. :beerchug:

Bill