Muffler mod failure

[junkman]

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

 

[junkman]

The tool i am thinking of for thread inserts ,it collapses those aluminum inserts to a mushroom shape on the inside .

 

[P.M.P.]

You should try to braze it back on.

 

[jake wells]

self tapping metal screws try those.

 

[mdavlee]

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

 

[junkman]

You should try to braze it back on.

I want to be able to change the screen ,the screens help muffle some noise .

 

[P.M.P.]

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.

 

[Warped5]

I like your rivet idea ... but would have never used aluminum.

Got any steel or stainless rivets laying around?

 

[Canadian farm boy]

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]

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

 

[Mastermind]

We use steel rivet nuts.

 

[srcarr52]

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.

 

[Brian Simonseth]

In sprint car racing they have these pop rivets with twice the size washers on them I wonder if they would work

 

[Nitroman]

self tapping metal screws try those.

Use these and bend the edges of the 288 deflector over onto the head of the screw with a few taps of a cold chisel; they won't come loose.

 

[skidooguy]

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.

 

[WKEND LUMBERJAK]

Stainless/steel rivets should hold. till you drill them out.

 

[CR888]

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.