So years ago I bought a brand new SP2 catback for my 95. Now its on my 99 with the O2 bung plugged. Over time on our lovely New England roads, the weather has rusted out the welds on the muffler baffle via tailpipe. Now the baffle is completely broken loose and rattle like an infants toy. I cant extract it from the tailpipe as its the same diameter as the muffler outlet. I've tried with long needle-nose pliars, breaker bar, demolition bar (basically any tools that are long enough to get in there). I really do not want to resort to cutting off the muffler tip then welding it back on. A new catback/muffler is out of the question. Anybody have any clue as to how I can get this matter sorted out? Any help would be greatly appreciated.

 

You're going to have to cut and weld something unless you can manage to bend/fold/cut the baffle inside the muffler somehow. Maybe cut a slit in an inconspicuous place on the muffler.

 

Well, I have come to the conclusion that since i can fit most of my hand right up the tailpipe before it tapers down to the 2.5" part closer to the muffler, i may try to see if I can reach the broken welds with a TIG welder and possibly tack it into place. Although the other end of the muffler will still have broken welds as well. Its worth a shot IMO and may be enough to shut it up.

 

Good luck getting your hand and TIG welder inside while holding your filler rod and trying to tack it in place.

Best option, open the exhaust like a can of sardines, fix it and weld it back together.