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Question:

what is the cheapest way to fix a hole in a muffler?

or do I have to buy a whole new muffler/pipe assembly1996 volvo 850 turbo, 189,000 miles

Answer:

Use what ever you brought it home from the store inRadiators do not get hot enough to cause any problems even if you forgot to remove your meal.
Clamp a piece of aluminum foil or aluminum roof flashing over the hole with two big stainless steel worm drive clampsHome centers sell the same worm drive hose clamp types used on auto hoses that are much bigger for plumbing applicationsYou can daisy chain two of them together to make a bigger clampIt works great on an exhaust or tail pipe tooAlso, use a wire coat hanger to hold the pipes up to the body of the car to keep the exhaust from breaking loose.

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