how to patch holes in a thin muffler

[Lafytafy]

On my Suzuki, the muffler is very thin and I have tried to weld a patch over the holes but I just melted the metal. my welder is cranked all the way down but still, I have no luck. What do I do?

[Batman]

So what kind of welder are you using?

I know with my TIG, I can vary the output with a pedal, which is really handing on things like thin metal. I can adjust the puddle as needed with the foot control. 

Another option would be to take it in somewhere. It might not be too bad of a price if you pull it off and just bring it in somewhere.

[Gwbarm]

Like you iv never had much luck at welding mufflers, I usually patch it with something like Rock Hard Muffler repair or something similar, while I look for a replacement, it will last a couple of years.

[Saskatchewaner]

I also just cheat with muffler repair cement. If it's not a ridiculous size hole and you don't care what it looks like you can just cut a patch out of tin, apply the muffler cement, and hold it in place with hose clamps until it dries. Once you get that stuff hot it hardens right up. 

[Mech]

The trick to welding up or patching over holes in thin rusty steel is to go right around the hole laying down a light weld far enough back from the edge that it doesn't eat it away, then either spiral in laying weld into the edges of the weld till it's fill to the center, or, make a patch to fit that weld.

Welding slightly back from the edge lets you get a heat dissipating bead down closer to the edge that you would manage if you gradually follow a melting edge back and back.. It also lets you assess the extent and viability of the repair before you get a patch half attached and then finding out it's not going to be big enough.

[Lafytafy]

I will try that. Thanks Mech