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Muffler mod failure

junkman

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The third port i have had on the hybrid failed last weekend ,it was a stock 288 husky deflector ,i had held by 2 3/16 rivets ,well they must have vibrated the aluminum rivets to wear and fail ,so now i need another attachment method ,i have some allen bolts with locknuts i can use ,i could weld nuts to the inside so they do not rattle off and get in the piston ,but that requires more time ,bead blasting welding etc ,or i could try these nut inserts that i use for bodywork ,they install like a rivet ,but are aluminum so wondering longevity ,appear to be stronger than a rivet ,plus the bolt will hold them in place if ever did come loose ,i use them mostly for automotive mirrors on truck doors .
the failed part and now is starting to melt the brake handle muffler mod  saber hybrid 1-26-16 tach 019.JPG muffler mod  saber hybrid 1-26-16 tach 018.JPG muffler mod  saber hybrid 1-26-16 tach 014.JPG muffler mod  saber hybrid 1-26-16 tach 024.JPG
 

jake wells

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self tapping metal screws try those.
 

mdavlee

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Bolt from the inside if you don't want to weld.
 

P.M.P.

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I want to be able to change the screen ,the screens help muffle some noise .
Makes sense I have a cheap version of the tool you have for the aluminum threads .Used it for a ladder rack on a minivan workd good so far.
 

Canadian farm boy

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The aluminum thread serts will fail just like the aluminum rivets. The vibrations from the running engine are the killer here. Personally I would use self tapping metal screws with some blue loctite and then if the screws come lose I would weld nuts to the inside of the muffler like tree monkey does.
 

idiotwithasaw

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How about stick a bolt through from the inside and weld it in. Then cut it off flush with the nut?
 

srcarr52

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I've tried rivets before too with the same result. Now I use a M4x0.7 press in nut. I pull them in using a bolt and then tig weld it on the outside to the sheet metal, very clean result.

IMG_1833.jpg
 

skidooguy

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A fender washer on a stainless rivet would be better than nothing but would suggest welding bolt from the inside of the cover. Hope my farmer way of thinking helps you out.
 

CR888

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Its important IMO to be able to service (clean) the spark arrestor screen. I think what Randy and scarr do would work well. When I get a new saw I always remove muffler bolts and put some high temp copper or zink based anti sieze lube on the threads. Since doing so muffler bolts come out easily and smoothly.
 
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