I have a Fox 3.2 on my AW Edge 540 and recently I was flying the plane and one of the muffler bolts came out and the muffler got loose.

My question is:
The bolt that went through the muffler and into the engine to keep the muffler on didn't go very far into the threads on the engine. Either there were not enough threads where the bolt went in or the threads there were stripped somehow. Now, what do I do from here? Can I retap the threads to a larger size...retap them farther...? I will try to get pictures within the next few days if needed.
Thanks a million

That's what I did to mine tapped out larger and deeper and no more problems.

you can tap it out to a 1/4-20 thread and not even have to drill it out I do mine that way and never have any more problems

Awsome! I was hoping for a fairly easy fix. Thanks for the quick replys.

When you tap out the holes I recommend that you use the correct "numbered" drill for the tap you are using and use the correct high-speed steel "bottom tap" ( that is - not the pointed kind.) This is designed to tap dead-end holes. Use a lubricant when you tap aluminum and clean the hole regularly while doing it. Q-tips and solvent works well to remove the filings. You will be much happier with the result.

the muffler bolts on a sachs 3.2 are not dead end holes and don't requir a botoming tap

I would recommnd using a 10-32 Helicoil it will work and be stronger. I had the same problem with a 2.4

Well, we decided to tap it out one larger in metric to 6mm. The lower picture is the new threads. Thanks a bunch for all the replys!