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Well, I decided to try my hand at re-skinning my existing muffler, since the outer wrap was absolutley rotten.

This is what I removed -



Only two bands held on what was left of the outer wrap, which covers the insulation blanket that surrounds the main muffler. Even though the outer cover was bad, good news was that the original Nelson muffler was still in good condition.

After I removed the rotted outer cover, I used a putty knife to carefully remove the insulation blanket from it (go slow, the insulation is pretty fragile).

Next, I cut a 10 1/2" wide by approx 16 1/2" long piece of 0.025 inch aluminum sheet (uncurl the old piece and measure the length to make sure. Scribe a line about 1/4 inch in from each long edge, this is where the retaining tabs will be cut. Cut evenly spaced, triangular notches along each edge to make the retaining tabs.

Carefully place the insulation blanket back around the main muffler body and wrap the new cover over the insulation to keep it in place. Use three, evenly spaced, 3 - 5 inch adjustable clamps to secure the new cover. See the photo below, which shows the retaining tabs and clamps already positioned. Keep the clamp adjusters aligned and located approximately as shown (approx 4 o'clock position when looking directly at the end of the muffler [that does not have the exhaust outlet] see last photo for correct orientation), to keep the adjusters from interfering with the oil cooler support (that the installed muffler will eventually rest on) and/or the muffler heat shield when the exhaust is re-connected to the engine.



Next, take a small ball peen hammer (or something similar) and slowly work around the edge to roll over the retaining tabs.



Once the tabs had started to roll over the edge of the main muffler, I finished the crimp of the retaining tabs with pliers (needle nose pliers also worked well).



After completing both ends, all that is left to do now is paint with Case Hi-Temp Muffler Paint. A few dimples on the edges, but all in all, a secure, functional outer cover.

 

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That is a neat way to repair a muffler.I usually build new mufflers,but if the internals are good then why not just re-skin it.


Maynard
 

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As a high school shop teacher for 30 years and a Case owner for 40+ you have done a very good job of demo the muffler wrap. I noticed my end cap went bad about ten years ago and replaced it and at the time I was thinking that this was a much cheaper and easier way then buying a whole muffler (compared to the older tractors). I may need to replace the whole wrap soon and just want others to know that this is not something that is hard to do. Just follow the great directions here.
 

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Thanks for sharing you pictures...I really like the way you refurbished the exhaust system! Great job Man!

Cheers
Darrin

.
 

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Discussion Starter #9
Thanks much guys, I really appreciate the compliments! The worst part of that job was the fact that I picked the hottest, muggiest day of the summer to do it. Completely brutal and ice cold beer immediately awaited me upon completion (as much as I wanted to pull from the mini-fridge in the garage)!

DCP54 - My hat's off to you. I have alot of respect for anyone that can teach skills and positively affect the lives of young people like that. Most school districts today, have really dropped the ball big time on their vocational tech programs and it really needs to come back.

My father was a high school Industrial Arts teacher for 35 years until he retired. I learned so much from him, there was nothing he couldn't fix or build and he was a great teacher! I've worked for a major aerospace company for quite awhile now and at one time had taught airline mechanics how to maintain and overhaul hydromechanical transmissions coupled to big AC generators. They were jet engine-driven, capable of providing 40 kVA to 120 kVA, 400 Hz, AC electrical power to an aircraft. Had to prepare lots of training materials in those days and had a ball doing it! I felt alot like my father in those days as I had my own shop, just like he did!
 

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What type of material did you use for the skin? Have a Case 444 Kohler that I'm having difficulty getting aftermarket type mufflers to stay on. Most after about an hour or so, shake loose at any pipe thread.
 

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Donens,

the outer sheet metal coverings for the under hood mufflers are still available through a dealer. As for the problems you're experiencing with your after market muffler, one of the dealers might have a New Old Stock muffler available for a reasonable price. It never ceases to amaze me with the NOS parts the dealers here can find. Tim
 

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donens
You should have started a new thread for your problem, that way you would have had more replies.

drhulv
HE said in this thread
After I removed the rotted outer cover, I used a putty knife to carefully remove the insulation blanket from it (go slow, the insulation is pretty fragile).

Next, I cut a 10 1/2" wide by approx 16 1/2" long piece of 0.025 inch aluminum sheet (uncurl the old piece and measure the length to make sure. Scribe a line about 1/4 inch in from each long edge, this is where the retaining tabs will be cut. Cut evenly spaced, triangular notches along each edge to make the retaining tabs.

If you want to just buy one complete you could start a thread in the Everything Else Section.
Buy/Sell/Trade/Wanted Bulletin Board

There are a lot of members with extra parts, they might be willing to sell you one for a good price.

bigman
 
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