Welding of the muffler by one's own hands

Even the quietest engine emits significant vibrations during operation. In particular, these are sound fluctuations. Spent gases tend to get out as soon as possible. Therefore, this noise is generated in the system. To reduce and modify it, the car uses an exhaust system. It combines a whole set of elements. This is the exhaust manifold, the resonator, the corrugation, and also the silencer. The latter and performs the basic function of damping sound vibrations. But over time, the element wears out. Why this happens and how to repair the muffler by our own welding, we will consider in our today's article.

Symptoms

How to determine the need for repair of this element? All is very simple - while the engine is running you will hear a characteristic sound of the exhaust gas. It will be very loud, sometimes whistling. Also some of the exhaust gas can leak into the interior (in this case, you also need welding the muffler corrugations). Smoke will not dissipate from the exhaust pipe, but from the bottom, and from different sides. Thus, if the muffler has started behaving in this way, then it has warmed up or rusted. Experts recommend a complete replacement of the element. However, a cheaper way is to weld the muffler with your own hands.

Causes

Usually the life of this element does not exceed two to three years. Why does he serve so little? It's all about the conditions of its exploitation. The muffler from the first day of operation is in the mode of increased loads. So, the element is exposed to moisture, salts from the outside and high temperatures inside. The differences in heating are simply enormous. Of course, no metal of such loads can withstand (and if it does, such a muffler will weigh at least 10 kilograms). In addition, the internal walls of the element undergo vibration. They are somehow extinguished through the damping cushions that are attached to the body hooks. But this does not mean that vibrations are excluded in the silencer chambers themselves. Also it is impossible not to mention the very location of the element. It is located in the rear of the body. All dirt and water are sure to be on its surface. In addition, the muffler is one of the lowest parts of the car. Overcoming steep climbs, you can easily hook on its lower part on the asphalt or other surface. Yes, the element will not crack. But the partitions inside can be deformed. But it is on them that the quality of vibration damping in the exhaust system depends .

Repair by our own hands - we prepare the tool

So, our exhaust became terribly loud. Exit from the situation - welding, repair of the muffler. For this we need:

• Welding machine (it is better to use a semi-automatic inverter with a wire diameter of 1 millimeter).
• A set of tools (ring and carabiner keys).
• A piece of sheet metal. It is desirable that its thickness is of the order of two millimeters.
• Bulgarian with a set of cleaning and cutting discs.
• Sandpaper.
• A metal brush.

Getting Started - dismantling the item

Having prepared all the necessary tools and materials, it is necessary to proceed to welding the muffler. First you need to get to the exhaust system. Inspection is best done on a pit or trestle. In the absence of this, we jack up one of the body parts and climb up to the bottom. Usually the element rusts from the side of the pipe connection to the "jar". Next, we pick up two keys and untwist the clamp. We pull the silencer out of the pipe grooves outwards. Note that the element may become imprecise. In this case, you need to shake it from side to side, expanding the opening of the intake pipe. It is better to weld the muffler when it is removed. It is rather difficult to do work locally (and it is not safe, because there is a gas tank nearby).

We open the jar

It happens that the exhaust system works loudly, but no obvious signs of rot or cracks are detected. In this case, it can be assumed that the muffler burned inside. It can be a perforated tube or its partitions. Therefore, to accurately determine the diagnosis, mark out the necessary fields and open a part of the "cans" with the help of a Bulgarian. Bend off the excess sheet of metal and cut or welded again the bar. At the end of the work, the sheet is bent and baked from all sides.

Features of welding

Why should you use a semi-automatic device? As practice shows, this method of welding is the most gentle for the silencer, since carbon dioxide does not allow the metal to change its structure and overheat. When working with the exhaust system, do not allow "gaps". The seam should be as flat and tight as possible. Otherwise, gases under pressure (and it is very high in the system) will burst into free gaps. All this will be accompanied by a loud unpleasant sound. In the event that the muffler is welded from the outside, a pipe of the correct diameter should be prepared. Cooking on rotten metal does not work. But cracks "semi-automatic" you can grab. Therefore, in neglected situations, we cut out a new piece of pipe (it is important that it be of suitable diameter) and weld it into place of the old one.

Why can not you just cut off the rotten part and weld the "jar" directly? The fact is that the silencer has a limited free stroke and if its position shifts, the cushions will be constantly in tension. And if you cut off even more, then the silencer does not fit into its factory place.

Painting

The final stage of welding the muffler is its painting. The applied enamel layer will reliably protect the metal surface from negative factors. It is worth noting that ordinary paint will not work - the humectant will be heated up to incredible temperatures (over 350 degrees Celsius). Therefore, all the enamel will simply burn out. At the same time, a characteristic odor will be released. But what to do in this situation? The silencer should be treated with a special, heat-resistant (powder) composition. It can be dyes from the series of KO 828 and 8101. It is better to use products in cans. So the enamel will evenly lie on the surface and cover all vulnerable and hidden areas. Only two layers are sufficient, so that the heat-resistant paint provides reliable protection and extends the service life of the muffler.

Welding of a silencer with argon - what are the features?

This is a modern technology that allows you to connect parts from steel and metal alloys. The operation is carried out in several stages. First the surface is prepared (peeled off with a metal cutter and degreased). Then the details are connected by "tack". Then a metal rod is laid on the seam line. At the final stage, the rod and the part are welded. During welding, argon gas is used. Oxygen does not enter the part, since argon enters the welding area under high pressure. This technology provides high strength joints, as well as tightness of the seam. The service life of such a silencer is an order of magnitude higher than that of a semi-automatic machine. But minus the technology in the high cost of equipment. Fortunately, there are a lot of companies that provide such services as welding the muffler and replacing the corrugation. The latter is also installed in the pipe on argon welding. The cost of these services is about three thousand rubles, including the price of the three-layer corrugation itself.

Conclusion

The serviceable muffler is a guarantee of a comfortable ride of the driver. After all, no noise insulation will not save, if from under the bottom gaps are bursting with cotton and a pungent smell. Also note that in the running cases, a reasonable way out of the situation will be a complete replacement of the muffler. Moreover, its cost is very acceptable. And you can install the element each - it is enough to have a pair of keys and a new collar (we thread the thread with a graphite so that the bolts do not turn sour). By the way, a silencer is installed (no matter whether it is new or repaired) for a special sealant. They grind the tip of the tube seat. So we will ensure maximum tightness and do not let the gases leak out through the small technological cracks.