If a tailpipe has a rusted hole in it, what is the proper procedure to repair it?

When dealing with a rusted hole in a tailpipe, the most effective and reliable procedure is to replace the assembly. This option addresses the root cause of the problem, as a rusted tailpipe is indicative of degradation, potentially affecting its structural integrity and performance.

Simply cleaning and welding over the hole may provide a temporary solution, but any existing rust could continue to spread and cause further issues. Patching with glue or wrapping with exhaust tape can serve as short-term fixes but do not resolve the underlying problems associated with rust and deterioration. These methods may lead to premature failure or additional repairs down the line.

By replacing the entire assembly, you ensure that the exhaust system operates effectively and safely, minimizing the risk of leaks that could lead to harmful exhaust gases entering the vehicle cabin or affecting engine performance.