How to Fix Exhaust Pipe without Welding

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As for gear heads, our cars’ exhaust systems are the parts we mostly ignore. After all, we have other complex things to worry about. Not until a broken exhaust pipe affects the car engine and your normal travel plans turn non-viable.

To evade high repair costs, today, you’ll learn how to fix exhaust pipe without welding. It’s just a simple DIY, and within a few minutes, you’ll resume on the road.

When an internal combustion engine runs, it burns fuel, and as a result, fumes and most engine noise are expelled through the exhaust pipe.

The fumes are hot and contain harmful particles that are reduced and cooled in the catalytic converter.

Afterward, they pass the exhaust muffler, and most noise is reduced. This process helps reduce toxins and noise that may pollute the environment.

However, because the exhaust pipe is located underneath the car, it’s prone to;

  • Snow ice
  • Salts
  • Road grime
  • Speed bumps
  • Potholes

As that’s the case, the exhaust system needs much attention, just like other car components.

How to Fix Exhaust Pipe without Welding

How to Fix Exhaust Pipe without Welding
Exhaust Pipe

This article will share five effective methods that you can choose to fix your exhaust pipe. Let’s dive in;

First, you’ll need the following items;

  • A sandpaper
  •  Acetone or other alcohol-based substance.
  •  Heavy-duty scissors
  • A piece of cloth

Before carrying out any method, use sandpaper to scrub dust and rust from the exhaust pipe. Afterward, use a piece of cloth and acetone to wipe it clean.

1. Using Exhaust Tape

In most exhaust kits, you will find exhaust tape. But if you don’t want to purchase an exhaust kit, you can purchase an exhaust pipe tape separately.


  • Cover the leaking hole or crack using the tape.
  • Make at least two layers to ensure its firm.

This method is most effective on smaller holes.

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How to Fix Exhaust Pipe without Welding
Exhaust Pipe

2. Using Epoxy

Epoxy is good at sealing small holes or cracks.


  • Gently stir the Epoxy to mix.
  • Use a small piece of wood to spread it on the leaking hole or crack.
  • Give it time to dry before starting the engine.

3. Using Aluminum Patch

The aluminum patch will sort the problem if your exhaust pipe is broken.


  • Use a pair of heavy-duty scissors to cut the aluminum patch depending on the area you want to seal.
  • Apply epoxy on the aluminum patch.
  • Wrap the patch around the exhaust on the broken part.
  • Apply epoxy on the patch edges.
  • Secure both aluminum patch edges with hose clamps.
  • Using Hot Glue


  • Apply hot glue on the leaking holes or cracks.
  • Give it time to cool down.
  • Using Exhaust Clamp
  • Using heavy-duty scissors, cut a sheet from stainless steel tin.
  • Wrap the sheet around the cracked area then exhaust clamp over it.
  • Fit the bolts and tighten them.

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How to Fix Exhaust Pipe without Welding
Exhaust Pipe

Symptoms of a Faulty Exhaust Pipe

If your car exhaust system is faulty, several symptoms may signal you to take action. Let’s take a look;

1. Poor Fuel Economy

A leaking exhaust pipe affects the normal exhaust pressure. Due to this, the O2 sensor signals the Engine Control Unit (ECU). 

Once the ECU senses any fault, it cannot balance the engine timing, and excessive fuel is injected into the combustion chamber, leading to wastage.

2. Higher Emissions and Noise

Due to excessive unburned fuel, the exhaust will emit much smoke as a result. On the other hand, the exhaust muffler reduces the engine noise.

But if the exhaust pipe is leaking before the noise gets to the muffler, most sound escapes through the leaking points.

3. Engine Misfiring

Because the ECU cannot signal proper engine timing, fuel is injected into the combustion chamber and misses fire from the spark plugs.

4. Engine Power Loss

Power loss will occur as a result of improper timing. The engine accelerates at a slower rate than normal and much power is reduced.

5. Fumes Enter the Cabin

The exhaust pipe aims to reduce harmful particles and noise before releasing the fumes at the car’s rear. If the exhaust leaks around the engine, the fumes will enter the cabin through the ventilation.

6. Damage of Surrounding Parts

Most exhaust fumes leave the combustion chamber when so hot. If they leak before undergoing the cooling process, they damage the surrounding components.

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How to Fix Exhaust Pipe without Welding
Exhaust Pipe

Troubleshooting the Exhaust Leakages

After noticing any of the above symptoms, troubleshoot the exhaust system to locate the leaking areas. To carry out the process, you need;

  •  Wheel ramps and axle stands – car jack may not be safe when getting under the car.
  •  Safety glasses – the car underbody contains dust, rust, and debris.
  • Heavy-duty apron – exhaust may contain rusts and other stains.
  •  Leather gloves – some rusted metals may be sharp for your bare hands.
  • Soapy water

This article will share four methods you may choose while troubleshooting. But before you start, ensure your exhaust pipe is cold.

Method 1: Start the car engine and inspect the exhaust pipe. Move your palm around the exhaust pipe to feel the leaking fumes breeze. At this point, you don’t need a glove, but be careful not to hurt your palm.

Method 2: Plug the tailpipe with a piece of cloth and have a helper accelerate the car. When pressure builds up in the exhaust system, you will see the fumes move out through the holes.

Method 3: Spray soapy water around the exhaust pipe while the engine is running. You will notice air bubbles on any leaking holes. You can carry out this process if the holes are tiny to be felt in method 1.

Method 4: Use a leaf blower to push air into the exhaust pipe while the engine is switched off. Use the palm or soapy water method to know the leaking points. However, ensure the engine is cold before pumping cold air inside.

How to Fix Exhaust Pipe without Welding
Exhaust Pipe

FAQs on Fixing Exhaust Pipe

How do you fix a loose exhaust pipe?

Find mounting points on the car’s underbody and fix the hose clamps to hold the exhaust pipe. You can use as many hose clamps as possible to ensure the exhaust pipe is firm.

Can I fix my exhaust myself?

You can use the methods above to fix small leaking holes or cracks yourself. However, if the exhaust pipe high rusts, a problem with a catalytic converter and sensors, you’ll need a specialist.

Can I drive my car with a broken exhaust pipe?

In some countries, it’s against traffic and environmental conservation laws because the exhaust will emit toxic fumes. Luckily, you can fix exhaust pipe without welding. It’s just a 30 minutes DIY using the above-discussed methods, and you’ll be back on the road. 

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