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Using JB Weld to secure deflector on 390xp muffler

Bigmac

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Hey Bigmac. Did you cut the new exhaust hole the size of the deflector on your saw?
It’s currently a little smaller, but I will go back in and open it up to the max soon, I am playing around with a 372xp oe and will probably swap it on there and see how each saw likes it
 

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Thanks. Just making sure I don't go too big with the opening. My deflector is on of the medium sized ones from sawsalvage and definitely smaller than yours.
 

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Anyone ever try JB's "Exhaust" product?? Not for affixment / securing anything but as a gasket-maker, have always hated that, for clean mate-up's on mufflers, I can only rely on clean surfaces & tight bolts, no gaskets/goops/etc, their brand has never let me down and they make (2) exhaust products.. (again I'm strictly referring to using it for gaskets only, like the gasket under the deflector that you affix w/ nuts&bolts ;) )

Could he just make the entire muffler out of one gigantic chunk of JB Weld? :campeon:
ROFL! To be fair they do make a product saying it's good for exhaust part sealing, not same as being the body of something (kinda like how temps in the chamber are higher than aluminum's melting point but we don't..usually..melt pistons)

I like the nut-rivets as well, easy to put spark screen under as well if needed
These look AMAZING, what considerations when buying? Surely tin/lead won't be strong/heat-resistant enough for muff usage (affixing deflectors)

Silver solder or brass brazing will work with a mapp torch.
If one already has torches (butane & propane, various sizes), is there any "kit" you know of for "1-off" usage? I realllllly wanted to go the brazing route but turned out it'd be cheaper to just buy a muff that's already got it done professionally, than buy all the goops individually to affix a deflector -- kept googling hoping for some small-volume "kit" but to no avail, any suggestions?


Thanks for the kind and generous offer. I may take you up on it if I can't find someone locally to do it very cheap.
Outta curiosity, if you're seeking someone locally w/o knowing anyone (IE using facebook/craigslist/etc), would be real interested how it went & how you phrased your request, am in similar spot now pondering if I wanna get away from nuts&bolts :P

Hey Bigmac. Did you cut the new exhaust hole the size of the deflector on your saw?
It’s currently a little smaller, but I will go back in and open it up to the max soon, I am playing around with a 372xp oe and will probably swap it on there and see how each saw likes it
Thanks. Just making sure I don't go too big with the opening. My deflector is on of the medium sized ones from sawsalvage and definitely smaller than yours.
May I ask what size(s), specifically, you guys are using? I'm interested in-theory, and for my 660's, and have worked with the ~60%-exhaust-flange figure for my 660 but subsequently saw videos of guys with bigger holes (in the proper location IE rearwards, not short circuiting the exhaust pulse's "kickback" at the flange) getting more power than mine, in fact they went a size bigger (maybe 3X the OEM primary hole!) and it was still picking up power (sadly they didn't continue, to see where it drops off!! This is so important, because being a lil under that point is fine, going past it is a real error!)
 

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Anyone ever try JB's "Exhaust" product?? Not for affixment / securing anything but as a gasket-maker, have always hated that, for clean mate-up's on mufflers, I can only rely on clean surfaces & tight bolts, no gaskets/goops/etc, their brand has never let me down and they make (2) exhaust products.. (again I'm strictly referring to using it for gaskets only, like the gasket under the deflector that you affix w/ nuts&bolts ;) )


ROFL! To be fair they do make a product saying it's good for exhaust part sealing, not same as being the body of something (kinda like how temps in the chamber are higher than aluminum's melting point but we don't..usually..melt pistons)


These look AMAZING, what considerations when buying? Surely tin/lead won't be strong/heat-resistant enough for muff usage (affixing deflectors)


If one already has torches (butane & propane, various sizes), is there any "kit" you know of for "1-off" usage? I realllllly wanted to go the brazing route but turned out it'd be cheaper to just buy a muff that's already got it done professionally, than buy all the goops individually to affix a deflector -- kept googling hoping for some small-volume "kit" but to no avail, any suggestions?



Outta curiosity, if you're seeking someone locally w/o knowing anyone (IE using facebook/craigslist/etc), would be real interested how it went & how you phrased your request, am in similar spot now pondering if I wanna get away from nuts&bolts :p




May I ask what size(s), specifically, you guys are using? I'm interested in-theory, and for my 660's, and have worked with the ~60%-exhaust-flange figure for my 660 but subsequently saw videos of guys with bigger holes (in the proper location IE rearwards, not short circuiting the exhaust pulse's "kickback" at the flange) getting more power than mine, in fact they went a size bigger (maybe 3X the OEM primary hole!) and it was still picking up power (sadly they didn't continue, to see where it drops off!! This is so important, because being a lil under that point is fine, going past it is a real error!)


@Cerberus https://www.ebay.com/itm/255053816901?epid=1729641043&hash=item3b62646445:g:-BgAAOSwKfVXHlxK

The link above is what I use, otherwise type silver solder kit in the eBay search box for others.
 

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Colonel 428

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Cerebus. I used a medium sized pre made deflector from Saw Salvage. $5 and it's got enough extra metal to be able to "customize" the way you want it to fit. I was thinking of trying to find someone to stick weld it on for me but I ended up just opting to use 4 small self-taping sheet metal screws. Pre-drilled the holes in the deflector but not in the muffler. I'm very happy with the way it sits on the muffler. I cut out a square hole as big as I could in the muffler and still have enough metal to attach the deflector. It didn't make the saw (Makita 7900) any louder that I can tell. Had to richen the carb so I'm sure it burns a little more fuel but hopefully increased the rpm a little too. I don't have a tach to know before and after numbers but feels like minimal gains at best in performance. Hopefully it lets the saw run cooler which is kinda what I was after anyway...

Sent from my SM-G973U using Tapatalk
 

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Did you give up on the spot welder? Or it just won’t fit into the tighter spots? Been thinking about one

No, I still use it, only problem is not every muffler splits in two to be able to utilize it. So it's weld, braze, silver solder, bolt, screw, rivnut my way to success depending on the situ.
Also I replaced the 220v version for a 110v version and it works just as good for the thicknesses we work with.
 

Cerberus

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@Cerberus https://www.ebay.com/itm/255053816901?epid=1729641043&hash=item3b62646445:g:-BgAAOSwKfVXHlxK

The link above is what I use, otherwise type silver solder kit in the eBay search box for others.
SO many thanks SS!!! How many inches of soldering would it be fair for me to expect out of that kit? IE doing 3" per deflector (1" on (3) sides per deflector)

Also:
- I'm good w/ paints, fiberglass etc (and can grind/cleanup well) but never worked hot-metals like this, I can tell this is "gotta have the feel" to do it right, which to me is simply full-seal (aesthetics don't matter or rather i can't be arsed the time&$ for them in this instance!) Would hate getting this thinking I'll get 2 or 3 deflectors affixed, only to find myself next week "ordering kit #2, pretty sure I can move-on from test-scraps" lol!

- What metals are problematic here? If I'm "getting it" then this silver works on both steel 660's, and SS 2511's, is that the case? Are these 2 steels going to generally work w/ all the same welding/brazing/fluxing products? (I ask because my understanding is their being ferrous makes it a Yes but wanna know for sure)


Did you give up on the spot welder? Or it just won’t fit into the tighter spots? Been thinking about one
"Spot welder".....I'm picturing some mini-welder setup, "welding for guys whose workshop is whatever table's clear-enough for a tarp to be tossed-down" lol, have wanted to get a welding setup but never had plans for anything large, GG look into "spot welders" but would be eager for any entry-levels here (welding is the 1 big gap in my "handyman arsenal" and gotta cover it at some point, if it's $50 for silver-solder to do a few deflectors, or $75-125 for a "spot welder" that I'd be able to keep using, I'd be all over the latter!!)

Cerebus. I used a medium sized pre made deflector from Saw Salvage. $5 and it's got enough extra metal to be able to "customize" the way you want it to fit. I was thinking of trying to find someone to stick weld it on for me but I ended up just opting to use 4 small self-taping sheet metal screws. Pre-drilled the holes in the deflector but not in the muffler. I'm very happy with the way it sits on the muffler. I cut out a square hole as big as I could in the muffler and still have enough metal to attach the deflector. It didn't make the saw (Makita 7900) any louder that I can tell. Had to richen the carb so I'm sure it burns a little more fuel but hopefully increased the rpm a little too. I don't have a tach to know before and after numbers but feels like minimal gains at best in performance. Hopefully it lets the saw run cooler which is kinda what I was after anyway...

Sent from my SM-G973U using Tapatalk
Seems some saws don't benefit too much, have been VERY intrigued by this would love hearing ANYONE elaborate on why some saws benefit so much when others don't, I mean obviously it goes w/o saying "Those that got gains were more choked-up", obviously, but what I'm getting at is why one company's non-strato unit would have the tightest exhaust-exit // exhaust-flange ratio you've ever seen (2511t) while others (ms660) have OEM openings a bit over 50%-flange-area..

For how you describe affixing it, that's basically what I do, I make the surfaces as-if I'm prepping them for paint or glassing, I put heavy marine-grease on the interfaces and drill my pilot holes BUT I use nuts&bolts, have never tried self-tappers would be far too fearful of their failure (surprised to hear they worked at all to be honest, w/ the higher-displacement units I've found a need to tighten everything down to levels I never did on 60cc and smaller saws, 90cc's rattles everything loose would be interested if others are having luck w/ self-tap screws!
Someone posted riv-nuts which look fantastic, gonna be seeking a pack of them at local spots today (hoping for proper size, otherwise it's just easiest to use nut&bolt, and grind-off the excess bolt-shaft where it protrudes from the nut inside the muffler....we're not using acoustics in our mufflers so "smoothness of flow" is only important insofar as "the whole system" not rough edges inside it, if that makes sense...all that matters is that exhaust pulse can expand and put pressure on the flange before it escapes the muff, so we can prevent excess charge-spill, which is the best we can hope for from canned-mufflers!)

Also, carb-tuning after muffler mods: Can anyone explain this "ELI5"? ("Explain like I'm 5"), I know the standard refrain would be "Open/CCW your H&L jets because you're now 'flowing more' through the unit" but, kinda embarrassing to say this but after muffler mods I rarely feel the machine needs much of anything...I should be clear I do not "over-do" them, but am not asserting that's the point....my thinking/curiosity is that this advice is basically conflating the richness of mixture coming-from the intake, 12.5:1 to 12.8:1 or whatever, but a higher-flow setup wouldn't be asking for changes in richness, but rather flow-through (IE the proper move wouldn't be "turn up the carb's richness" it'd be "get a new carb w/ appropriately up-sized throat", no? Thanks for any elaboration on this!

No, I still use it, only problem is not every muffler splits in two to be able to utilize it. So it's weld, braze, silver solder, bolt, screw, rivnut my way to success depending on the situ.
Also I replaced the 220v version for a 110v version and it works just as good for the thicknesses we work with.
ROFL it's equal parts comforting & worrisome that someone like you is still approaching it that way, sounds like how I describe my stuff "Hack hack hack my way til it works" lol, obviously you're doing it on another level but think your passage here shreds my idea of "1 product that'd let me always, continuously affix small metals" :P
 

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SO many thanks SS!!! How many inches of soldering would it be fair for me to expect out of that kit? IE doing 3" per deflector (1" on (3) sides per deflector)

Also:
- I'm good w/ paints, fiberglass etc (and can grind/cleanup well) but never worked hot-metals like this, I can tell this is "gotta have the feel" to do it right, which to me is simply full-seal (aesthetics don't matter or rather i can't be arsed the time&$ for them in this instance!) Would hate getting this thinking I'll get 2 or 3 deflectors affixed, only to find myself next week "ordering kit #2, pretty sure I can move-on from test-scraps" lol!

- What metals are problematic here? If I'm "getting it" then this silver works on both steel 660's, and SS 2511's, is that the case? Are these 2 steels going to generally work w/ all the same welding/brazing/fluxing products? (I ask because my understanding is their being ferrous makes it a Yes but wanna know for sure)



"Spot welder".....I'm picturing some mini-welder setup, "welding for guys whose workshop is whatever table's clear-enough for a tarp to be tossed-down" lol, have wanted to get a welding setup but never had plans for anything large, GG look into "spot welders" but would be eager for any entry-levels here (welding is the 1 big gap in my "handyman arsenal" and gotta cover it at some point, if it's $50 for silver-solder to do a few deflectors, or $75-125 for a "spot welder" that I'd be able to keep using, I'd be all over the latter!!)


Seems some saws don't benefit too much, have been VERY intrigued by this would love hearing ANYONE elaborate on why some saws benefit so much when others don't, I mean obviously it goes w/o saying "Those that got gains were more choked-up", obviously, but what I'm getting at is why one company's non-strato unit would have the tightest exhaust-exit // exhaust-flange ratio you've ever seen (2511t) while others (ms660) have OEM openings a bit over 50%-flange-area..

For how you describe affixing it, that's basically what I do, I make the surfaces as-if I'm prepping them for paint or glassing, I put heavy marine-grease on the interfaces and drill my pilot holes BUT I use nuts&bolts, have never tried self-tappers would be far too fearful of their failure (surprised to hear they worked at all to be honest, w/ the higher-displacement units I've found a need to tighten everything down to levels I never did on 60cc and smaller saws, 90cc's rattles everything loose would be interested if others are having luck w/ self-tap screws!
Someone posted riv-nuts which look fantastic, gonna be seeking a pack of them at local spots today (hoping for proper size, otherwise it's just easiest to use nut&bolt, and grind-off the excess bolt-shaft where it protrudes from the nut inside the muffler....we're not using acoustics in our mufflers so "smoothness of flow" is only important insofar as "the whole system" not rough edges inside it, if that makes sense...all that matters is that exhaust pulse can expand and put pressure on the flange before it escapes the muff, so we can prevent excess charge-spill, which is the best we can hope for from canned-mufflers!)

Also, carb-tuning after muffler mods: Can anyone explain this "ELI5"? ("Explain like I'm 5"), I know the standard refrain would be "Open/CCW your H&L jets because you're now 'flowing more' through the unit" but, kinda embarrassing to say this but after muffler mods I rarely feel the machine needs much of anything...I should be clear I do not "over-do" them, but am not asserting that's the point....my thinking/curiosity is that this advice is basically conflating the richness of mixture coming-from the intake, 12.5:1 to 12.8:1 or whatever, but a higher-flow setup wouldn't be asking for changes in richness, but rather flow-through (IE the proper move wouldn't be "turn up the carb's richness" it'd be "get a new carb w/ appropriately up-sized throat", no? Thanks for any elaboration on this!


ROFL it's equal parts comforting & worrisome that someone like you is still approaching it that way, sounds like how I describe my stuff "Hack hack hack my way til it works" lol, obviously you're doing it on another level but think your passage here shreds my idea of "1 product that'd let me always, continuously affix small metals" :p

I haven't kept track, but would hazard to guess about one to one inch ratio maybe.
It(silver solder) will work on ss and carbon steel even joining the two together.
Spot welder is alright if you put deflectors on a lot of Stihl's.
Gains are like grains of sand, you never know how many you can pinch in your hand until you do it.
Nothing wrong with screws and nuts.
I have a plethora of different made deflectors and packs of pipe all to meet each job individually along with the different ways to attach them so it will not only function as intended but fit and look like it was made just for the job.
If your mod allows more air to flow through the carburetor it will pull the necessary amount of fuel. Usually too many changes are made to have this work just so, sometimes a little more change is required for the proper end result then.
I'm plumb tuckered after this many questions. Lol
 

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Regarding those self-tapping SCREWS, would those be reliable to secure a 1x1" flat square of 16g sheet-metal so I can cover-over this hole in my 2511t muffler:
20220420_164729.jpg
[hole is on "lower side" in picture, though that'd be the muffler's leftward-side of its front panel, I made my hole here because it's the only way I know to access the (3) rear-to-front baffle holes allowing gas from rear, to front, halves of the muffler....I cringe at the idea of just boring-through this baffle at the point of the OEM exit, that short-circuits the entire muffler...]

I used a similar approach on my cs590 but that has pre-tapped holes on the top so I just had to drill holes in the sheet-metal square and find appropriately threaded fasteners, have never used self-tappers (have never trusted them, I have many dozens of specialty fasteners from Tapcon to adhesives I just never trusted self-tapping screws for metal, always seemed like something that'd "automatically" come loose in-time :/ )

BUT it's the only way (short of brazing/welding) that I can patch my hole, and then simply enlarge the OEM exit (NOT touching the baffle-wall behind it of course!) as my primary&only muffler escape, IMO the best possible layout for the 2511 (well it's really just Echo's layout, "flowed out", lol, nothing special about it just doing what they could've if emissions didn't matter!)
 

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No, I still use it, only problem is not every muffler splits in two to be able to utilize it. So it's weld, braze, silver solder, bolt, screw, rivnut my way to success depending on the situ.
Also I replaced the 220v version for a 110v version and it works just as good for the thicknesses we work with.

Can I ask what your using for a spot welder? HF? If so how do you like it...thanks!
 

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Can I ask what your using for a spot welder? HF? If so how do you like it...thanks!

The first 220v one I was using was from Harbor Freight and the second was an eBay special. They both worked well for what I was doing and I wouldn't be surprised if they came out of the same factory in China. Couldn't say that I would want one for production work, but for every now and then muffler deflector I think it will last me a good long while just fine.
 
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