Looking at rear muffler repl...

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by hobbit, Mar 1, 2020.

  1. hobbit

    hobbit Senior Member

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    New England's winter salt can eventually kill even the finest stainless exhaust
    components, and by now I don't know what's still holding my rear pipework
    from simply falling out onto the road. It's also developed a leak a little way
    behind the coupler with the bolts/springs, so it's time to replace it. I went to
    the local dealer and simply sprang for the rear system, which comes as a unit ...
    muffler and the rear pipes, and the bolts/springs/gasket to attach to the front
    half of the system [which still appears to be okay, and fortunately not stolen
    yet]. The concern is the rearmost hangar peg welded to the chassis, which is
    rusted down to probably a fraction of its original strength, so that needs some
    kind of replacement or reinforcement.

    I don't have a welder or the necessary chops to competently use one at the
    moment, but am wondering if there's some sort of bolt-in alternate solution
    that's at least a step or two up from baling wire. Ideas? I suppose I should hit
    the auto-parts store and browse the offerings for straps and clamps and such.
    I know, a decent exhaust shop could probably make quick work of this, but if
    there's something I can reasonably do myself that's preferable...

    I have yet to put the car in the air and really have a good look, that's a warmer
    weather project, but a little pre-research can't hurt. I might also consider some
    kind of DIY cat shield as long as I'm under there, given the numerous horror
    stories here and elsewhere recently! The car spends a lot of time relegated to
    the "back forty" since getting the Kona EV, but I'm not ready to give it up yet...
    and it's great to see this community here still so vibrant.

    _H*
     
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  2. valde3

    valde3 Senior Member

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    Is the beg really that bad? Generally (on other cars) those begs mounted on body are still good for multiple muffler replacements. I think you could just fit a bolt or alltread in place of that beg by drilling through "frame rail". It doesn't even need to be exactly at the same point. You could just bend it to get it aligned. All you would need is bolt or alltread, nuts, and washers. Also you could use many types of universal exhaust mounting bracket or just bend a mounting bracket out of that allthread then you could bolt those through floorpan and still use factory rubber mount.

    How is the underside looking otherwise? How bad is the rust? Where is it worst? These are just my interest so they have nothing to do with your question.
     
    #2 valde3, Mar 1, 2020
    Last edited: Mar 1, 2020
  3. SFO

    SFO Senior Member

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    Welcome back!
    Maybe one of the 'anchor bolt' options below, thinking 90/45 degree. Maybe it could be bent up a bit in the vice.

    If there is no vice access, you might try a J-bolt, Hook bolt (square), U-bolt (square) after cutting off one end to make an easy hanger. Doesn't the dollartree have some cheapo coated hangers (bike hooks), it wouldn't be fancy or heavy gauge, but something to experiment with.

    Bet the exhaust shop could properly sort you out for very little, as they must be replacing rotted hangers on the regular.

    [​IMG]

    Check into some of the expanded metal, there are affordable galvanized and aluminum options.

    [​IMG]
     
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  4. hobbit

    hobbit Senior Member

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    Well, here's a progress report to date:

    . Prius exhaust

    I'll probably hit up the exhaust shop next month and just git 'er done. I've also got
    a DIY cat-shield in the works. Does anyone worry about trapped heat with the
    more closed-off versions of those, like the "cat security" type?

    _H*
     
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