RE: am i lucky, or does this happen all the time
jj 213, here is a little tip that very few will listen to. It is very simple but doesn't do justice to the I-pod and $200 sneaker crowd, but it saves mufflers. I have planted a number of mufflers way back when we first started using them. I have never seen where any sprouted and grew a muffler bush, tree, whatever. I don't care to plant them.
1. Using regular sissors, you can cut some aluminum from a pop can. Cut it far bigger than the engine exhaust outlet.
2. Now press the alum. against the exhaust, run your fingers around it, including the screw holes. You have defined the size of the exhaust.
3. Take a sharp x-acto type knife and cut away the INSIDE of the alum. I always leave a 1/16" or more inside just for security.
4. I use the x-acto point to make my screw hole. Perfection is not needed but use a drill if you must.
5. I always tap out the muffler holes for 6-32 or bigger on BIG engines. Use black socket-head screws. They are at the home / hardware stores cheaper than a hobby shop. Your call.
6. Now you can clear off some of the outside alum. You can tidy it up after mounting your muffler.
7. That thin metal gasket will do the trick. I never use locktite or anything. I have not planted a muffler in years. I do every so often tighten the screws but they seldom take any. The soft gaskets that come with the engine are strictly POOP!
8. Each time I remove a muffler for general maintenance, I make a new gasket. I make these for backplates, for head gaskets, etc. Easy to make, perfection not required, cheap, and works great. My Kind of Thing!.