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.

RE: TT 40 Muffler Rebuild
 

The stock muffler bolt was replaced with a 4-40 all thread bolt.

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.

RE: TT 40 Muffler Rebuild
 

Yep, thats what I do. Only I use 6-32 rod. Nice thread.

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.

Denis

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.