How Do I Reconnect the Muffler Heat Shield?

I don't think there's a simple answer to your simple question.

The correct way to fix the problem would be to remove the muffler to provide access, remove the rusted hardware from the underside of the body and install a new heat shield and new bolts (or else use oversized washers to compensate for the oversized holes in the old heat shield.)

 

Is there enough room to drill another hole toward the outside edge of the heat shield and put a screw in? Not sure if it is safe to drill though (anything delicate such as wires behind?). Another thought was J-B Weld. Yet another was to fashion some sheet metal spring widget to wedge between the heat shield and the muffler. None of these are ideal though.

By the way I like your method of organizing your tools by keeping them in their original (store display) packaging. I use the same trick for some of my tools also.

 

Interesting problem. You actually got me to take a look at the muffler & heat shield arrangement on ours. Since you don't want to take the muffler off, is it feasible to disconnect the muffler brackets, fore and aft of the muffler thereby allowing the muffler to drop a few inches? That extra space might give you the room to get tools in there to reattach the heat shield. Just a thought.

 

An excellent thought.

In addition, if Tony removes the stiffening brace, that might allow the muffler assembly to swing laterally as well as down, thus providing even more access to the work area.

I think he should buy new rubber mounts in that case, so that the old ones can be cut off without placing stress on the muffler attach points which look pretty rusty.

 

I just reattached my muffler heat shield using oversized washers like you mentioned. Problem solved! Although, I did not remove the muffler. I just struggled to fit a small enough wrench, a socket wrench, and my fat hands above the muffler to unscrew the old bolts that were securing the shield.