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On my K8 I have a freeflow muffler with titanium tip and bolt in silencer.
Last week I noticed the outside of the tip was covered in black powder and the muffler starts making a lot more noise.
The leak is at the side where the tip is bolted to the silencer..
I will not take the silencer out, noise already is deafening in the car at 2000 to 2500 rpm..
Does anybody have any experience with this? Is there anything I can do about it? Can it do damage to the muffler?

Here's a picture of before the leakage.

Take a after pic.

Its not that big of a deal, the muffler is just breaking in, just like a resonator would. They all get louder after time. As for a small leak, thats not that big of a deal I would think, take some pics of the soot so we can give you some more info. I wouldnt be worried though

If it concerns you, and you don't plan to take the silencer out, you could maybe JB Weld it, or take out the screw, rivet it, and fill in the rivet with a dowell, or JB Weld. Or, take out the screw, thread the hole, and bolt it with a bolt that has teflon tape, or threadlok on it.