I had a muffler leak where the gasket goes and I didnt have access to a gasket. So I took it off and shaved all the old gasket material off and took some sand paper and sanded both surfaces clean. Then I took some dynamite RC cleaner and sprayed the surfaces clean to remove all oil and sand gritt around the contact point. I then bought some high temp RTV gasket maker and smeared a small amount on both conecting points and then screwed them together as tight as i can and cleaned off all excess. I havent ran it yet to see if it leaks yet.

I have done this many times, the main thing to remember is that too much RTV will restrict the exhaust flow.... That is to say, how ever much that squeezed out and you had to wipe from the out side, is now dried on the inside. A very light bead will do. Apply the bead, tighten just enough to squeeze a little out (Don't wrench it down) and then let it cure. Once it is cured (over night) you can take out the screws one at a time to add thread lock and tighten the flange down evenly on the RTV gasket. This will give you a long time seal and no possibility of restriction to the exhaust flow.

I've also made gaskets out of old playing cards for both the exhaust and backplate. Worked fine. I've seen the same success with using cardboard off the back of a tablet.

The King of Spades works better than the Queen of Hearts.

I don't like using gaskets anymore. I use RTV only and if the surfaces are bad I use a Lansky Knife Sharpening Stone to dress up and resurface muffler and engine surfaces. I dont use much RTV at all and I wipe off the excess after installing the muffler, cant even see that RTV is used and the joint does not leak at all.

If you look at a new Jett Bar Stock engine, RTV is used between the Cylinder and Muffler adapter. My new 90 lx does not even come with a gasket for the muffler and if you inquire.....it does not need one[sm=thumbup.gif]

Richard

I do the same, RTV gaskets. I've found that fibre exhaust gaskets have a habit of blowing out, allowing the muffler screws to become loose, and then it's the ole' muffler hunt. With RTV, the gasket is too thin to blow out, and you can torque the bolts down securely, once it's set up.

J

My brother and I have (or had) seven two stroke engines from .25 to .61 (ASP, Magnum, OS, Thunder Tiger) and have not used exhaust gaskets on any of them. The aluminum surfaces were machined smooth at the factory and we haven't had any issues at all with a metal to metal seal.

But the Joker makes the Royal's flush.