ORIGINAL: Arrow IV
Anyone else like cleaning your expensive top of the line gas engine as much as me when the fricken muffler to block connection leaks???...... What's the deal on the best way to connect your mufflers to prevent any leaks? I've heard everything under the sun: gasket only, no gasket and use Permatex, use Permatex and the gasket, use the red Permatex, use the black Permatex, use the copper Permatex, lions, tigers and dude enough already... What say you gents?
On all my engines, I lay a piece of Teflon tape (plumber's tape) across the mating surface, pop a couple of small holes at the bolt locations, and a small slit in the exhaust opening.When the engine fires, it will break free the remaining tape barrier in the exhaust stream, leaving a Teflon gasket at the mating surfaces.
I like the really wide tape, making it easier to hold in it place as I bolt the muffler on; however, if you have only the narrow stuff and need to cover a larger area, just lay down a couple of pieces, overlapped - the exhaust area itself will then be partially open already and will blow fully open upon starting the engine.
I don't bother with Loctite on the bolts, but I do make sure that they are really honked down tight, and I try to remember to check them every decade or so. As I have experienced a couple of muffler losses in the distant past, and have had bolts loosen in more modern times (NOT due to my gasketting technique), I usually do one more thing - especially on my OS engines, as those things seem to be prone to divorcing their muffler. I use some safety wire wrapped around the muffler body and extension, then around the cylinder head once. Taht way, if the thing does loosen, I don't lose it.
I have been dong this for over 20 years, it works for me. "Your mileage may vary..."