Blown muffler rebuild - Easy

A swing and a miss: The repaired section held up great. However, an identical crack developed on the opposite side of the muffler. My guess is that the cracking is caused by the pressure, but I am not sure why it keeps happening in the same section of the muffler. As much as I hate admitting defeat, I am going to punt and buy a new one.

I realize this is an old thread, but if anyone reads it, let me know what you think. I've read most of the comments, but i haven't heard anyone say they just removed the baffle, and then repaired the cracks and reinstalled the muffler. That is my plan, because the baffle is loose, and in my case would be a pain to repair. We cut a hole today, and we plan to cut out the baffle, repair the access hole and the crack in the muffler (reason it was taken out to start with), and reinstall the repaired muffler without the baffle. I'm guessing noise without the baffle will only be 10-15% louder than with the baffle, but that's just a guess. One thing is for sure, the muffler without the baffle will be much quieter than the "Y" pipe suggestion. Does anyone have experience with the hull hugger muffler (2 inlet/1 outlet) with the baffle removed? Thanks.

Before I start...everyone forgive me for resurrecting an ancient thread. My questions entirely are related to this repair thread so I didn’t want to start a new one. I have a 96 Sport with a leaking hull hugger muffler. It’s got a Centek label on it so I think it’s been replaced before and is not original. Because the pictures that were posted in the original thread are no longer available due to the web sight crash earlier this year, does anybody have any copies of pictures they can re-post to the thread?

From the descriptions about doing the repair I still have no clear idea about where to cut into the muffler to attempt the repair. Maybe even a rough drawing somebody could snap a picture of an upload?

Lastly, I have been strongly considering putting a fresh air exhaust system into this boat. If I cut the muffler open and remove the baffle, effectively turning the muffler into a glorified y-pipe and then install the fresh air exhaust, would the fresh air exhaust work as a muffler since the exhaust outlet would not be exposed to the air while under power?

Jim, these pics and videos are incredible. Like they say a picture is worth 1000 words!

jhersey29 wrote: https://1drv.ms/f/s!AvCtCf0yHSvwj6BkzGN6y1O-fc9YjA Been a long time and don't really remember what I said in the videos. This was to repair the blown wall issue where it flapped. Might help. If it's just leaking I don't think you need all off this. Maybe just a hole worn through on the bottom from rubbing om the hull for years.

I just spent the last hour trying to get these hoses loose. That will have been the hardest part of this project I think. I got the muffler out about five minutes ago and the internals look really solid I was able to get my arm in there and there’s no movement or sound. My only issue is as you suspected, just a small crack along the bottom because the rubber bushings we’re not existence between the muffler and the hull. This will be just a small fibreglass patch and the addition of some rubber on the bottom and I’ll be golden!

The area that wore through was the highest spot on the bottom surface of the muffler. It had also worn through the paint on the hull. There was no rubber backing like they were supposed to be I guess.

I’m not sure why you would ever have to take the risers off to remove the exhaust system. You just have to do it the right way wink wink ;). I put some soap on the exhaust tubes coming down from the risers and then use the heat going to heat up the rubber sleeve that connects them to the muffler. I used a screwdriver to break the bond between the hose and the pipes and then I used a oil filter bite wrench in the middle of the rubber hose to twist it back over the Exhaust hose. It was tedious but it worked just fine. I just rebuilt the engine for spring so all of my gaskets and bolts on the risers are brand new and I’m sure would’ve come loose but I didn’t want to replace gaskets again.

Good point. Mine are pretty dang short. They barely sit 2 inches on their respective fibreglass pipes and just barely enough for double hose clamps to seal.

The video's are still active and shared. Try a different browser. I wouldn't cut in unless you are really annoyed by the chatter sound. You might be able to reach the broken area via the inlet and outlet ports. Find someone with small hands and use gravity as your friend. I'd find away to watch the videos before doing anything. I'd also consider buying a new muffler. They still produce them.