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No Cost Exhaust System Ciggarette Smoking Test - New Muffler with Bad Seam

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Published on Oct 4, 2012

This is how I found the leak in a bran new cat-back exhaust system. I had thought I was having trouble with the flange joints but it turns out the leak was from the seam of a new muffler.

That muffler was hard to find for that car - and I do have a welder. So the plan now is to remove it, weld it, and then re-install it.

In the video I miss-spoke at 3:15 about "where I cut it and welded it back". That was from cutting one of the bolts at the flange interface shown at 1:40. So the leak in the muffler is as it was manufactured. I'm surprised it wasn't pressure tested when it was manufactured.

My next operation will be to remove the whole thing, pressurize it while not on the car and fine the exact locations of the seam problems. Either I'll be able to fix them by hammering them tighter or I will weld them.

What was also telling was that when I started the car after the test the cig-smoke came in through the HVAC (heater vent and AC).

DSCN1181.MOV

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