I have seen many exhaust systems have problems due to incorrect mounting and
using the wrong parts. Part of craftsmanship is having the required
resources such as tools, space, and good materials.
You have to give some thought as to why your muffler failed at the inlet.
Some combination of age, corrosion, heat etc. A contributing factor for this
failure here is miss alignment to the cat causing stress and loose parts
allowing for vibration movements.

Where the brackets are connected to the engine mount you need good hardware
here. Most important especially with the slotted holes in the bracket is the
washers. Now since you got your hardware at local sources most likely the
washers are garbage. Yes washers also come in grades. You want washers that
are designed to be used with PC 10.9 or 12.9 fasteners. From experience you
really want good fasteners here also.
While corrosion is not as much of an issue where you live as it is here I
have seen many bolts become one with the aluminum in that bracket.  You want
those fasteners to have some type of zinc or "organic" coating on them. Do
not just relay on the black oxide types. An Anti-seize compound here can be
you friend. While the bolts for the straps do not have to strong plating or
stainless screws can also be helpful in the future.

Speaking of doing a good job since the muffler is off finish removing the
catalyst and inspect it from both sides. Any looseness or burning-blocking
of the guts means time for a new one. I've replaced many a muffler due to
the cat breaking up and filling the muffler with the pieces.

Dennis

-----Original Message-----
From: Vanagon Mailing List [mailto:vanagon@gerry.vanagon.com] On Behalf Of
JRodgers
Sent: Tuesday, August 13, 2013 10:54 PM
To: vanagon@GERRY.VANAGON.COM
Subject: Re: Paint job pricing

For that kind of money - I would do it myself. Might take a while - but it
would be right what I finished. That's my biggest problem with the crafts -
crappy workmanship. Dedication to the craft is minimal in most places. You
can still find it -= but boy does it ever take some digging.
I've had to fix to many jobs that were plain crappy. Live through to many
horror stories.

Just like my muffler nightmare - my problem - but it's gonna be right when
I'm done, no questions asked. The muffler will not fall out in the street!

I bet Jim is happy with his home paint job. He knows it's right.

John

On 8/13/2013 9:11 PM, Jason wrote:
> I wouldn't expect much for under $3-4K in terms of quality.