Wow. I salute this effort. I have never heard of anyone repairing a muffler before.To continue Piratetip's "practice welding" theme, I'll share the finished HKS exhaust. I will never weld another HKS muffler again, at least not til next weekend. The casing was super thin sheet over slightly heavier, so once the pool formed the surface tension would suck it back and reveal the second layer full of mill scale and carbon. I tried TIG, but it was slow going and used a ton of shielding gas and hated the dirty metal. I tried MIG, but couldn't get a reliable arc with the low WFS I had to use to keep from blowing through. I settled on sloppy, dirty, tolerant oxy-acetylene - a size 0 torch tip and 1/16 filler for welding the perf tubes (worked beautifully so even though I'm not a pro, I'm not a complete moron) but had to size up to 3/32 filler when welding the casing just to cool the puddle enough to not lose it. Even then it was frustrating and slow-going. I finally got everything closed and since it was going to be hidden til the rest of it rusts away, I threw the last bit of VHT silver I had on the bare metal and parts that'll show. The rest of the exhaust had some kind of ceramic coating that held up remarkably well to 25 years under the car and then torch heat.
I figure I had about 35 hours of work in it, with replacing the elbows, rewelding the braces and cutting and forming new tubes to opening and closing both resonators and the muffler. Looking back it was crazy to do but the exhaust was unique enough I wanted to save it.Wow. I salute this effort. I have never heard of anyone repairing a muffler before.
Is it hot there? The dashboard is all cracked. I see it on many cars. Are they stored outside?Got it half done. Pillar pod sanded to fit nicely, got all the lines and wires run for the gauges. Tomorrow I've got to pick up a small brass tee, mount the solenoid and get all the vacuum lines plumbed. Then just have to make the final connections to the add-a-circuit, find a ground and reassemble.
Looking back I probably could have run these without taking the gauge cluster and everything out but I had to remove the lighting circuit for the old gauge, which I had inconveniently run the same exact way.
This one has lived the past ten years outside, and with summer temperatures at 95F/35C it gets very hot inside. I've tried to keep a reflector on the windshield but it's time to replace it.Is it hot there? The dashboard is all cracked. I see it on many cars. Are they stored outside?
Be careful, in my experience if the left out in the heat like that, your windshield rubber seals would have dry rotted and will let water seep through, causing rust.This one has lived the past ten years outside, and with summer temperatures at 95F/35C it gets very hot inside. I've tried to keep a reflector on the windshield but it's time to replace it.