best way to seperated rusted muffler

[twitch101]

i have an OEM muffler for my 200es i need to seperate the header from as they have rusted tight together and it seems near impossible to install as one piece. i cant get the header to seal on exhaust port.

[Grizzlypeg]

It could be a real challenge if its rusted. If you have a torch and heat the outer tube and do some tapping on it, it might expand the outer tube and loosen some of the rust scale that is wedged tight between the two tubes. In the end, it might be easiest to just make a lengthwise relief cut on both sides of the outer tube (use a small angle grinde and a zip disk), pry it slightly to separate, then mig weld it up afterwards.

[harryredtrike]

i agree heat is your friend here.can you still see the seam?heat till orange.

[3wheelmecca]

go where the joint is/was and either run a pipe cutter on it or a thin hacksaw blade, then heat, it will physically break the rust bonds. Did the trick on my 200E.

[twitch101]

yup i have an acetylene torch at work i can get a hold of and a welder i can probably "try" to use. all i know at this point is that its rusted up good enough to be airtight and perfectly strong without the clamp.