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Tailpipe Repair

Yahoo Message Number: 9255
I recently mentioned that our '98 Intrigue's through-the-sidewall tailpipe (including the muffler flange) had rotted off by the time we arrived in Myrtle Beach, SC. Here's what I did to perform a temporary repair to get us back to NJ. I bought a 24" length of galvanized 6" heater duct at the local Lowe's store. The duct's joint wasn't crimped together, so I planned to roll it tightly to the required 5" diameter. I also bought a 12" pair of straight tin snips to cut it to length (approx 18" was desired) and I needed a pair of snips for my coach tool box, anyway. And I bought a 5" muffler clamp at the local NAPA store.

Using the tin snips, I shortened the heater duct to 18," which would allow it to be inserted 10" inside the muffler with the other end terminating at the outer end of the original tailpipe. Leaving the rotted off tailpipe and its muffler clamp in place, I slid the tightly rolled up duct through the tailpipe and into the end of the muffler. It sprung back into position snugly. The new clamp was installed on the original tailpipe to stop the tailpipe from protruding too far. I then drilled three holes near the end of the tailpipe, through the heater duct which was inside it and bolted them together, drawing the duct tightly against the inner surface of the tailpipe, thereby reducing the inner diameter only slightly. I wasn't concerned that the assembly would go INto the muffler as I drove. I also didn't do anything to seal the loose joint in the heater duct, figuring that it wouldn't be a problem 'cause of its location at the coach's rear, rather than under the passenger compartment as in a front-engined vehicle.
The bottom line is that the repair worked well on our ~600 mile trip home.
And now I have to decide if I want to replace the muffler with an original equipment type or with a Flowmaster 40, as also suggested. Any comments one way or the other?

Our engine is a Cummins C8.3. The original muffler is mounted East/West with a 5" inlet in its front and exhausting out its left end. And I bet it costs "a lot."

Dick (& Geri) Campagna
'98 36' Intrigue #10571
Mfd: 11/97