So... the title is fairly descriptive: the little "arm" that secures the muffler has rusted through and broken. In a few days, I will be bound for a weeklong roadtrip, ultimately culminating in my complete relocation, so I don't have time to take it to a shop and have it re-welded. According to Leif, it doesn't appear to be the normal kind, so apparently just going to AutoZone and picking up a new muffler hanger (as I have done with all previous vehicles) isn't an option.

Any suggestions for securing it for the next 2000 miles, until I can get moved, settled in, and locate a good shop to fix it?

I can post pictures later, if that would help - I probably wasn't very descriptive.

 

Well, coming from NE, we always had mufflers rust out. Two options

1. Get some "baling wire" from home depot. Usually found in the fencing department, its a very heavy gauge wire. You need wire cutters (big ones) to cut it and just wrap it around the muffler and the body hangar
2. get a wire coat hanger and unwrap it. Same idea as the baling wire except its MUCH stiffer and harder to use

good luck OM

 

should be able to bend some 1/4" rod to shape and weld it up. I'd call around for someone who can take a drop-in, and then just go and do it. It will take about the same amount of time as the bailing wire, and will last longer.

Matt

 

I think I just need a new strap -- where does one get these? The strap is broken in 2 places: the vertical bit that extends down the left (exterior) side of the muffler as well as the horizontal bit that extends over the top of the muffler. It is thoroughly dead and would probably be easier to just replace the whole damned thing, as opposed to attempting any kind of repair.

PS -- in the meantime, we have rigged both mufflers with wire. The right muffler strap, upon examination appears about ready to give way as well. Thanks for the suggestions, Chows - very practical: I never would have thought of it

 

It happened to me last Winter...

Since I did the One-Ball mod, I still had the other "strap" at home... So I got it installed. I took 15 minutes at the garage to install it and it was all good.

 

My '03 did that at a year old. Warranty covered

 

This is a common occurrance

Simple, and durable fix is to head to a decent auto parts store and ask for a 'heat shield clamp', which is essentially a huge diameter stainless hose clamp. These are used to hold heat shields on mufflers and catalytic converters in OEM and replacement systems. Another fix is to find the same sort of large clamp at Home Depot (or similar) that is used to attach flexible ductwork in heating-a/c systems. If you cannot find one large enough to wrap around the muffler, the clamps can be attached end-to-end to make larger versions. Simply wrap the band clamp (not to be confused with 'that one time at band camp') around the original hanger and screw it down tight.

 

^^ +1 Acehardware also has those large hose clamps...look in the
sewer section were they sell garbage disposer stuff.

 

^^ Oooooh... good to know! Thanks

 

a crapload more than the bailing wire/coat hanger and won't work much better. I'm guessing it isn't covered by warranty???

 

Obviously a broken muffler strap is a sign from the MINI Gods that it is time for a new cat-back exhaust! (I warn against angering the MINI Gods, as they will zap your ECU and make you drive a rented Hyundai for a week).

 

When I took my car in for the 50K end of warranty inspection and had 20 things fixed, they forgot to replace the broken strap; so I called them and took it back and had them fix it. They told me that a lot of MINI have that happen because of condensation on one side from the exhaust.

Apparently, MINI fixes stuff with blinders on - meaning that if you don't bring it to their attention then they are not going to fix it. Good luck!

 

That's exactly what I said when Leif pointed out that the weld points were also starting to rust; "Oooh! Good!"