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TT 40 Muffler Rebuild

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Old 08-28-2011, 10:11 AM
  #1
sahartman21
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Default TT 40 Muffler Rebuild

The Thunder Tiger Pro 40 muffler comes apart during use. One method to fix the muffler is to replace the stock muffler bolt and J-B Weld the unit together.

I used an existing muffler that had to be re-glued. Begin by taking it apart and cleaning parts with Brake Cleaner.
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Old 08-28-2011, 10:12 AM
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Default RE: TT 40 Muffler Rebuild

The stock muffler bolt was replaced with a 4-40 all thread bolt.
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Old 08-28-2011, 10:16 AM
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Default RE: TT 40 Muffler Rebuild

Mix a small amount of J-B Weld and glue parts back together.

The all thread bolt should be tightened relatively tight.

I installed the muffler back on the airplane and set it out of the way to dry.

This process took about 1/2 hour and eliminates most muffler issues.
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Old 08-28-2011, 05:29 PM
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Default RE: TT 40 Muffler Rebuild

Yep, thats what I do. Only I use 6-32 rod. Nice thread.
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Old 08-29-2011, 07:54 AM
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Default RE: TT 40 Muffler Rebuild

I never use the stock muffler bolt for even one flight. I replace it with a 6/32 threaded rod with lock nuts on both ends. I don't JB weld anything. Never had a problem after that.

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Old 08-29-2011, 12:20 PM
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Default RE: TT 40 Muffler Rebuild

I even go so far as to put (2) 2-56 x 3/8 socket head sheet metal screws to fasten the front and back halves together. THEN I put safety wire around the whole thing so that if it STILL breaks, at least the back half will be hanging on so that I can use it again instead of losing it in the grass.
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