National Aeronca Association Bulletin Board

Trying to install a new muffler (HansenWilson type) from WagAero and rear pipe fits perfectly but the front doesn't align perfectly. Funny thing, this is exactly how the old one fit and it ran like this for twenty years plus. However, it had a small leak around the clamp because the pipes never came together properly.

Any suggestions without replacing or remaking the exhaust manifold from the cylinder?

Jack D.

Today I tried (on the suggestion of a friend) heating the pipe on the inlet of the old muffler to cherry red all around and using another pipe as a lever, tried to bend the inlet slightly. It bent but the side of the inlet cracked because the thin metal would not hold a cherry red condition long enough as I heated all around.

Anyway, anybody else have any suggestions? Help!

Jack D.

guest wrote:Today I tried (on the suggestion of a friend) heating the pipe on the inlet of the old muffler to cherry red all around and using another pipe as a lever, tried to bend the inlet slightly. It bent but the side of the inlet cracked because the thin metal would not hold a cherry red condition long enough as I heated all around.

Anyway, anybody else have any suggestions? Help!

Jack D.

Jack,

Just sitting here at work reading your post. First did it bend enough and all you need is a good weld/Brazer that can work with that material? If you still are not where you need to be you might be working on the wrong end. They make new exhaust flanges that can be welded to your stack from the Cylinder. Cut off the old one and buy a new one from Wagaero or any shop, bolt up the flange clamp the pipes together from the Muffler and mark the pipe and flange. Remove pipe and flange give it to a welder and go to it.

I am not a welder but we have a great one here at the airport that does it all for gas tanks, complete airframes, not much he can not do.

Mike Kne
Dayton, Ohio

You can weld it with a TIG welder using Argon or an inert gas. It needs
to be backed up with gas, if not, it will crack soon. Do not braze, which
means the the use of Brass. In the aircraft world, brazing is the use of
brass. Welding is the use of steel/stainless. I would have sent the muffler
back to them explaning the problem. If they don't what the problem is
they may keep making them the same way.
Best of luck!

The original muffler fit the same way as the new one, not lining up at the correct angle. The stack dropping down from the cylinder has a strange look to it; like it had been cut and rewelded to a new angle, so I suspect the stack may be the problem.

How much trouble is it to get the stack unbolted from a C65? I can't see its condition very well unless I start removing baffling, etc. (I thought this was going to be a simple job...) I mean, are there problems getting them off?

Thanks to all replies!

Jack D.
11AC Chief (rebuilding) and Taylorcraft BC12-D (flying) N44057

guest wrote: (I thought this was going to be a simple job...)
Jack D.
11AC Chief (rebuilding) and Taylorcraft BC12-D (flying) N44057

Well it can go either way, not knowing which one does not line-up. They
should have brass exhaust nuts on then, which can take the heat and
should come off with a socket and swivel. I have one socket that I
ground the OD to make a thin wall socket out of it for more clearance.
Sometimes the stud comes out with it but thats OK. The nuts come loose
from time to time causing the casket and or flange to burn away, which
might have happen ans someone rewelded a new flange on and got it in
the wrong position.

Jack, do not know your situation but you need to work with and under the
supervision of you trusted A&P / AI , most will work with you and most do
not like to see alterations / repairs that they were not awear of when the
annual come around.

They have the tools and usually have seen this problem before.


Mike Kne

Mike,

Was going to suggest this a ways back and did not. Course Jack might be an A&P but not sure. Also would help if Jack would sign in and put a name on his profile. Might be someone on the forum who is close who could help with this. Cannot tell until we know where he is!

Exhaust can be a real bugger to work with at times...

Joe A

Sorry for the "guest" sign-in. I saw someone else do it and since I never got an e-mail to verify my membership, I assumed that it wasn't active.

However, I looked at the Membership list and sure enough, I am there at the end.

There are only two AIs on our field here in Western Pennsylvania, and one is an admitted spam-can lover. Doesn't like to work on tube n' fabric birds. The other fellow is a terrific, relatively young fellow but he is so busy, that I will not get the chance for him to look at the airplane for many weeks, when my annual is scheduled.

So, I'm trying to solve the problem on my own. I think I will buy an exhaust stack and see if I can put it on. Assuming the stack and muffler purchased from WagAero will fit together.

Thanks all,

Jack Dernorsek (hangarb7)
Rostraver FWQ, near Pittsburgh, PA
'46 11AC Chief (rebuilding S/N 869) and '46 Taylorcraft N44057 (flying)

guest wrote: There are only two AIs on our field here in Western Pennsylvania, and one is an admitted spam-can lover. Doesn't like to work on tube n' fabric birds. The other fellow is a terrific, relatively young fellow but he is so busy, that I will not get the chance for him to look at the airplane for many weeks, when my annual is scheduled.


Thanks all,

Jack Dernorsek (hangarb7)
Rostraver FWQ, near Pittsburgh, PA
'46 11AC Chief (rebuilding S/N 869) and '46 Taylorcraft N44057 (flying)

Jack,

Not far from Ohio! There is a great place in NE Ohio "Barber" and you
might already know about it. http://www.oaafly-in.com/ They are all
tube and fabric, click on the site and look around. Might want to contact
them, they might have a line on an A&P /AI.

Also keep posting here alot of advise here all good, some great!

Mike Kne

Barber Field? Certainly I know about Barber Field in Alliance, Ohio. I haven't had a chance to fly there yet but my Taylorcraft before I owned it made several visits.

The problem with an owner doing the work, particularly with a complete rebuild of an aircraft is that the AI really needs to be local. All of the mechanics in Western Pennsylvania are busy, busy, busy. I have found a few fellows that would travel to my airport, but honestly, they are older folks, and I'm trying to build a long term relationship. If I had my way, I would feel comfortable with an older gent looking over my shoulder; but in reality, the younger fellows don't like to sign off on someone else's approvals.

I love old airplanes!

Thanks for the help. Fly over for a visit sometime. Great restaurant on the field.

hangarb7@yahoo.com

Jack Dernorsek (hangarb7)
Rostraver FWQ, near Pittsburgh, PA
'46 11AC Chief (rebuilding S/N 869) and '46 Taylorcraft N44057 (flying)

Jack,

You might give Forrest Barber a call. He usually sticks to only doing work on local aircraft for people he knows, but he might be able to refer you to someone who knows rag and tube in Western PA.

Contact info is at http://www.barberaircraft.com

Also, I checked your user profile and it's now active. Not sure why an email didn't go out. Let me know if you have any trouble logging in.

foxtrot uniform

roger that

nkh

Hope you guys do not mind if I deleted the spammers post!

did you try calling the folks at AWI? 1-800 597 4315. I'm told they KNOW mufflers. May solve it over the phone.