Weld a small patch on it. A muffler shop should be able to do this.

-Andy

phew... sounds like you dodged a bullet Jay. That is great news!

I would just tig your muffler hole closed if it were me... Should not cost very much at all to get it done.

Shane

Yes I was greatly relieved to find the hole. Was supposing welding was the answer but wasn't sure about burning through the muffler.
Shane I knew you had some welding done, so it was tig?

Jay

yes, mine was tig'd

Is the noise once per revolution or at 6x if it’s at once per rev I don't think it’s the hole in the muffler. I had a noise as you describe and thought it was an exhaust leek it could only be heard if under load and never by just revving the motor, it turned out to be a rod bearing. If after you weld the muffler and are still looking for the noise in a month keep that in mind. Good luck!

Jay welding these mufflers can be tricky the metal is thin and burns thru easy so warn who ever does it to becareful.

Tim, almost positive :) its the hole. But I'm going to carefully check everything else when that is fixed. I'll be very nervous until then.

Tony, the thin metal is my concern as well. I'm going to have someone that is very familiar with these things to do the work.

Thanks guys.

Jay

I'm keeping my fingers crossed that this fixes it!

Who you gonna get to weld it?....one of the local muffler shops?

If you're worried about welding thin metal, clean the area well with some sand paper and JB weld it. I've done a few muffler holes this way. It's ugly, but will hold.

insert a ss screw w/ a lock-washer,