muffler

[Tedder]

2. My muffler is separating at the bottom seam. I've seen a post that Uncle Glenn does a welded patch fix for that. Given that I can stop in at London when traveling that direction (usually twice a year), is it possible to stop in, let the thing cool down enough to remove, and then "trade" (in the form of purchasing a rehabilitated one, and leave my core behind)?

Or is there anyone else out there that can help?

Tedder, in the beautiful thousand islands

[Nigel]

That is exactly how Glenn usually does it.  When he has a few that need repairing he sends them out.  Also you can contact Willys he may have one he can exchange or he can weld yours if you have an hour or so to spare.  
 

Nigel

[Willys]

Tedder, IF you have a few hours to spend I can weld yours while you wait.....by the time we get the bodywork off etc It may be cool enough to deal with wearing gloves etc....if you help it'll be faster also.  Depending upon how long it takes me to reweld it, and how bad the damage is, will depend upon how long it takes me to fix it.  I do not have any welded ready to go. Glenn has them all....
It normally takes me a good hour to do the welding fingers crossed.  I can also remove your CAT if you wish...just more time. Doing so will sometimes allow you to smell a small whiff of diesel while sitting at a light with the window down.....but other than that, it breathes better....just better flow.....both of mine have it done and neither blows black smoke and they are both mapped I think .  I have seen some smoke after mapping with their CAT.  I have welded one that was so choked up with soot that I was surprised it had any flow....took plenty of time to bang as much out as I could to finally get it to stop falling out while preparing it to be welded. 
Your call....I live in Pefferlaw an hour north of Toronto, bottom righthand corner of Lake Simcoe.  

[Tedder]

I've snapped a few photos. I don't think it's obstructed, so I don't want to remove the CAT (saving the environment and all that). I don't hear any sign of leaking yet. I'm trying to be pro-active.

[Willys]

This is typical, possibly a bit worse, but repairable..from what i can see...as i said it's just time. This whole seam will be banged, loosened and opened up and then wire brushed, slightly grown to clean metal, then clamped closed and welded instead of crimped. The repair should last years, but there are no guarrentees because i can't see the rest of the inside of the can. Mine has easily lasted a year without any signs of coming apart, just showing rusting again.  But zero holes or showing any signs of holes coming.
We must take the back body section off obviously to get at easily the manifold nuts, then the bracket that attaches to the diff.   I do not usually remove that bracket off the can as it's a real pain to reinstall so i just work with it as best i can. IF you want, make sure the manifold bolts are easily loosened before coming up here if you wish. I always worry about breaking studs and think of all the worse case issues and try to remedy them before it happens. But we can also do the same here. Hopefully a dry day as my shop is full with my rebuild of my summer car. I have tarps etc if we get caught off guard....lol. 

[smart142]

Willys was kind enough to repair 3 exhausts for me in the spring.

However they have disappeared - lost in the old warehouse.

So I would recommend that you take Willys up on his offer.

I'm not a welding guy!