Melted muffler intake

[IslandTimeInVancouver]

After running my engine with the seacock closed I overheated my engine. Yesterday I sought advice on how to replace the deformed hose leading from the engine into the muffler. Trouble replacing hose from engine to muffler

Today when I removed the hose I realized my problem is much worse than expected. The intake on the muffler has also melted in the heat. I would estimate it is a little over half occluded.

What are my options? I have a three week trip planned this weekend. I'd like to be able to take the trip. I note Catalina Direct sell a new muffler. The obvious downsides are the length of time to deliver and the difficulty of replacing the whole muffler.

I am considering simply replacing the hose and using the muffler in its current state. At least temporarily. I suspect the engine could make do with a constricted muffler opening. Particularly if I did not tax the engine. I'm also contemplating trying to saw off a quarter or half an inch from the top of the input tube (which is about 2 inches) because that seems to be the part that has melted. The very handy Diesel engines 101 suggests using epoxy to fix a cracked tube. I wonder if I could rebuild my tube.
http://www.c34.org/wiki/index.php?title=Muffler_Replacement_or_Repair

Thanks to all who assisted my question from yesterday.

Here is a birds eye view of the opening to the muffler:

 

[Stu Jackson]

In the link I gave you yesterday is this post:

http://www.c34.org/wiki/index.php?title=Repairing_an_AquaLift_muffler_(with_pictures)

There's also this:

http://c34.org/bbs/index.php/topic,6728.0.html

Good luck, it can be fixed.

 

[The Garbone]

Looks like time a new muffler unless you want to repair the one you have. Can be done if your handy and want to spend the time. Myself, I would just get a new one and be done with it as CarbonMonoxide in the cabin is something I do not relish.

 

[kloudie1]

It would be OK (for the weekend) unless you run at very high loads.. just make sure that the hose goes all the way (down) to an un-deformed piece of the inlet tube and securely clamp it there so there is no leak out of the hose. Repair it at first opportunity.

 

[Jack - La Paz Mx]

Why not gently reheat the tube with a torch and straighten it out?

 

[IslandTimeInVancouver]

I like that suggestion Jack. In the long run I can replace the muffler but straighten out the tube might be a good temporary fix. How much heat would I need to get the tube pliable? Would a hairdryer be enough or is there a tool for the job?

 

[Joetech]

If you have a fiberglass muffler, you can repair it with fiberglass tape and resin. It melted because you didn't open the sea water valve. Most likely destroyed the water pump impeller as well. If you have a poly muffler (like mine) maybe you can get the fitting straight but only a little heat from a paint stripper will work. I doubt a hair dryer will get hot enough. If its fiberglass heat will not work. You will probably have to replace the exhaust hose as well from the engine to the muffler. The inside is destroyed. outside could look OK.
Please don't ask how I know all of this.

 

[IslandTimeInVancouver]

Thanks all for the advice. I spoke with Catalina Direct. They were concerned about any fix other than a new muffler. Unfortunately they are back ordered. It seems Catalina is having trouble making this part.

 

[jeepbluetj]

I'd guess it's a Vetus or other standard waterlock muffler. SBO has em in the catalog: http://shop.sailboatowners.com/prod.php?1304. You'd just need physical size and inlet/outlet diameters to search for one.

Other marine stores would have em. (Defender, We$t, etc....)