My mower muffler has gone bad and the replacement is $280. So I'm looking for a low cost solution. What happened is that the front of the muffler came off. For a while I was able to crimp it back on, but now it's rusted to the point where that doesn't work anymore. The body of the muffler isn't rusted through, but the metal is pretty thin and corroded, so welding to it isn't an option.
The muffler is 4" diameter and the pipes are 1-1/8" OD. I also thought about adding some pipe to the existing pipes and use two small mufflers, but many of those install with pipe threads, and I'm also having a hard time finding 1-1/8" exhaust pipe and adapters. I'd rather not remove the entire exhaust, because it's held onto the engine with socket head capscrews and the hexes are stripped. Please excuse the grime and the half baked repair. My son was in the middle of cutting and had to do something. Any trick ideas come to mind?
tuna55
SuperDork
4/26/11 7:21 p.m.
My friend is restoring a Berkely and he was having trouble finding exhaust pipes that small. I think they were the same size. Check for motorcycle stuff. That's what the engine was that he was installing.
A friend's mower had the same problem. I wrapped the entire canister with sheet metal and rewelded everything. Basically rebuilt the canister around the old one. That was early last summer and it's still together.
Ive got a briggs muffler in good shape if you want it. Just gonna run a straight pipe out of the cart.
DIY 2 into 1 collector and a Kerker
Get a couple big tubes of JB Weld and a paint brush..... 
If you're looking to fab new or add on 1-1/8" DOM steel tubing is available. Also, 1-1/4" X .065W (1.120" ID) would slip over the 1-1/8 if needed. Look online for suppliers w/ sale by the foot. I use Dillsburg Aeroplane Works in eastern Pa. 717/ 432-4589. They don't do internet sales, phone only. They talk real fast so have your info and credit card ready.
That Cherry Bomb answer made me laugh. It's what I'd do.
DrBoost
SuperDork
4/26/11 10:52 p.m.
Yeah, I'd bite the bullet and remove those screws and fab up a simple exhaust. Trying to band-aid it is just going to mean you are going to have to revisit it every summer, often more than once. I hate cutting the grass enough as it is, if I have to keep messing with rusty exhaust pipes I'd hate it even more.
Cut pipes off flanges, weld on 1" pipe nipples, screw these on:
http://www.smallenginewarehouse.com/product.asp?PN=Muffler-36&desc=Briggs%20&%20Stratton%20Engine%20Parts%20Mufflers%20Muffler,%20screws%20onto%201"%20NPT%20pipe,%2
Okay guys. First, I can't weld on it, as the metal is too corroded and thin. The mower is a Toro 52" ProLine 2000, the engine is a 16hp 2 cylinder Kohler,and yes, the OEM muffler is $280. I already wear ear plugs, as I have 50% hearing loss in both ears. My kids often cut the lawn, which takes about 3 hours, and the mower is WAY too loud without the muffler and the engine doesn't run well without it either. I don't want them to end up like me. I liked the idea of cutting the pipes off at the flanges and welding on the threaded pipe, but there's no access to weld at the flanges.
I already tried JB Weld and it only held fo r a short time. I think the metal is just too corroded. My original idea was to cut the muffler off, get new pipes, clamps and mufflers and call it a day, but like I said, I can't find the pipe, the clamps or the 90 bend I would need for one of them, so for you guys that suggested that, an online source for these parts would be appreciated. I've been looking for quite a long time and haven't found what I need.
Exhaust bandage tape and several coats of hi temp por 15?
In reply to TRoglodyte:
Already tried that. If you look close, you can see remnants of the tape in the second pic. It actually worked better than the other band-aid fixes, but still didn't last long enough.
TRoglodyte wrote:
Lawn mower salvage yard?
He's probably right. Sounds like you need a used rider. Craigslist, my friend.
Edit: Or slap a Briggs on it and call it a day.
If they are too weak to weld, then any attempted repair is likely to be futile, or only postpone the inevitable. I can't really get an accurate sense of the size, but you might be able to cut off and adapt the flanges from the heat riser tubes on an air-cooled VW intake manifold. Someone here probably has one collecting dust.
tuna55
SuperDork
4/27/11 7:54 a.m.
I don't see the big issue. Grab some pipe from a motorcycle shop (or get some conduit, I guess) and a few pieces of slat steel to shape into flanges, weld some stuff together and get the pipes to a generic tractor muffler from the tractor supply store.
In reply to N Sperlo:
You're saying replace my entire mower? That would undoubtedly cost a lot more than buying a new muffler. Besides, it's a good mower. I'm not ready to give up on it.
I think TRoglodyte was implying that maybe I can find a good muffler in a salvage yard. I will look into that, although I'd still be faced with removing the flanges from the engine, which will be a lot of work.
Guys, I guess what I was hoping for here was not so much a method to fix it, but sources for parts to fix it. If I had a source for straight and 90 deg bent 1-1/8" exhaust tubing, and a way to connect the old with the new pipes, I would be set. Mufflers are no problem. I just can't find the pipes and clamps to do the repair with.
