rusted out muffler heat shield replacement?
10-15-23, 09:38 AM
#1
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rusted out muffler heat shield replacement?
Hi all,
The heat shield between the muffler and gas tank gave out. (it has two layers of metal with a water-absorbent feltish blanket sandwiched in between).
New (hah!) and used parts don't seem to be available. I'm thinking its a good idea to retrofit something there, before the gas tank bursts into what would be an explosive finale to my life. (After a 20 minute drive in cooler weather, the side of the gas tank was not much warmer than the bottom, so I'm thinking its an infrared radiation issue). Is there any info on how to improvise a heat shield, something I could bend up, that would offer protection that is better than ... nothing?
Does anyone know of a heat shield for another car that can be adapted here?
I'm thinking about bending up a piece of galvanized sheet metal and adhering a self-stick heat-reflective blanket to the muffler side might be the only solution. I'm not sure how well the self-adhesive will hold up to wind and water, but I can't think of another solution.
The heat shield between the muffler and gas tank gave out. (it has two layers of metal with a water-absorbent feltish blanket sandwiched in between).
New (hah!) and used parts don't seem to be available. I'm thinking its a good idea to retrofit something there, before the gas tank bursts into what would be an explosive finale to my life. (After a 20 minute drive in cooler weather, the side of the gas tank was not much warmer than the bottom, so I'm thinking its an infrared radiation issue). Is there any info on how to improvise a heat shield, something I could bend up, that would offer protection that is better than ... nothing?
Does anyone know of a heat shield for another car that can be adapted here?
I'm thinking about bending up a piece of galvanized sheet metal and adhering a self-stick heat-reflective blanket to the muffler side might be the only solution. I'm not sure how well the self-adhesive will hold up to wind and water, but I can't think of another solution.
Last edited by rmauser; 10-15-23 at 09:57 AM.
10-15-23, 10:39 AM
#2
I would use a piece of .60" Aluminum because it is easier to work with and it won't rust.
For insulation I have used DEI insulation with an adhesive backing. It sticks well if the surface you are sticking it to is clean. I use aluminum foil tape to seal the edges. I have this stuff all over the bottom of my race car on the passenger side of the floor, the side of the fuel cell, the bottom of the air box and on a header heat shield. It has held up well even after several races in the rain. https://www.autozone.com/sandpaper-a...xt=Heat+Shield
I would put the insulation on the side if the shield facing the muffler. For more heat protection you could even put this insulation on the side of the gas tank next to the muffler. Under no circumstances would I recommend putting header wrap on the muffler.....unless you just want to buy a new muffler after it rusts out.
For insulation I have used DEI insulation with an adhesive backing. It sticks well if the surface you are sticking it to is clean. I use aluminum foil tape to seal the edges. I have this stuff all over the bottom of my race car on the passenger side of the floor, the side of the fuel cell, the bottom of the air box and on a header heat shield. It has held up well even after several races in the rain. https://www.autozone.com/sandpaper-a...xt=Heat+Shield
I would put the insulation on the side if the shield facing the muffler. For more heat protection you could even put this insulation on the side of the gas tank next to the muffler. Under no circumstances would I recommend putting header wrap on the muffler.....unless you just want to buy a new muffler after it rusts out.
10-15-23, 10:52 AM
#3
Fabricated muffler shield
I had to replace a disintegrating tank shield to pass local safety inspection. I just put a simple curve into a sheet of aluminum. I am not a metal worker nor do I have specialized tools. It worked out pretty well. To strengthen it, the new metal was cut 1/4” larger in all dimensions, then folded over to create a double layer around the outer edge. Other than the simple curve and edging, I pop-riveted on a flange at the trailing edge which attaches to the rear muffler hanger bracket near the rear bumper. Also, there is a bracket that attaches the front inner corner of the muffler shield to another separate shield that runs left/right to protect the leading edge of the gas tank. I fabricated one of those brackets by bending and drilling a length of aluminum strap. I doubt you need to add a double-layer or insulation. Apparently thousands of rusty FB’s run safely with no shield at all. So even a rudimentary shield like my redneck fabricobble seem to be sufficient.
Last edited by Redawg; 10-15-23 at 11:05 AM.
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