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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 -
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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.
![]()
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.
