Exhaust Cracked recommendations & interior cable reroute.

I'm looking at this beat up thing and thinking, "couldn't this simply be made out of galvanized sheet metal as an owner produced part or minor alteration?" The scat tubing inlets could be reused from the old part. It would certainly hold up better and the weight difference would be negligible?
Jan

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Can't answer that question from a materials point of view, but you're dong the right thing by checking it over -- sure wish I'd done the same to mine when it was out and on the ground!! I was too focused on the muffler itself and missed some gross issues with that ^%$ed shroud! Could have saved myself a lot of time & aggravation had I checked it over more carefully. Oh, well... chalk it up to experienced gained!
 
How did you form the "ears" used to clamp the shroud together?
That bit isn't visible in your photo.
I would like to make a replacement myself but the "ears" bit still has me thinking how I can do that.
What grade and gauge aluminium did you use?
TonyN
 
tnowak said:
How did you form the "ears" used to clamp the shroud together?
That bit isn't visible in your photo.
I would like to make a replacement myself but the "ears" bit still has me thinking how I can do that.
What grade and gauge aluminium did you use?
TonyN
Click to expand...

I’ll have to try and dig up the material information. It’s soft aluminum maybe 3003 or 5052-0. I believe.032 thick. I bent the ears long on a metal brake then trimmed the legs to the length of the original.


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I have done the same out of aluminum and thin stainless. Put in a brake and over bend it. Takes some practice pieces to get the length just right or make a top and bottom half that over lap each other and held together with hose clamps lie Atlee Dodge makes for Super Cubs.
 
Just a quick note to add my voice to those who recommend Dawley for repairs. Found a crack in the rear crossover pipe at annual this year. My mechanic recommended Dawley and I remembered this thread, so mailed it off and within 2weeks had a piece that fit perfectly and was like new except for a support attachment ear. I’m back in the air and very happy with Dawley. Brian
 
From this thread I called Dawley on a # from their website this morning to inquire about "rebuilding" my muffler. The man answering the phone was at Aero Space Welding in Minnesota not Dawley in Wisconsin. Told me Dawley is no more. They have a PMA muffler no core required for $450 and it's "new". So ordered it.
 
Frank Green said:
From this thread I called Dawley on a # from their website this morning to inquire about "rebuilding" my muffler. The man answering the phone was at Aero Space Welding in Minnesota not Dawley in Wisconsin. Told me Dawley is no more. They have a PMA muffler no core required for $450 and it's "new". So ordered it.
Click to expand...
I heard that about Dawley just recently.
Not exhaust related, but I heard that Harrison (engine work) is also gone.
 
Harrison did my cylinder a short while ago. The A&P that overhauled my engine said he's used Harrison for over 20 years. Darrel was getting up there in age (as we all are)

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OK so Monday I called Dawley in WI and Aerospace Welding in Min answered. Shipped new PMA muffler same day for the cheapest price I could find. Received it today. Yes the third muffler in the pic is an extra I had and if I had to would have got me by for now but with this kind of service why not. Back on Sat. morning. Oh and yes oven cleaner and a scoth brite had makes the shroud look great.
 

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Ok three years since this post, just found the flame tube broken loose and covering the outlet. It seems Dawley is out of business so what is the current best choice for a new / overhaul muffler and current price you've seen.
 
Also best way to remove tailpipe without destroying it. I suppose since the muffler is trash cutting off the outlet pipe is a way. Tried using Aerokroil and heat ahd not too much force and no luck yet, might be time to break out the die grinder.
 
I can't think of the name at the moment, but I believe Dawley was absorbed by another welding company -- who are still in a similar business. Anybody remember who that is?
 
I sent some Maule exhaust to AWI and will never use them again. They were bought by Hartzell and they do not care about anything but making money. It was on the verge of Fraud. Acorn Welding was also bought by Hartzell, not sure about their work and ethics. Knisley is next on my list. https://knisleyexhaust.com/
 
Can or should any thing be put on tailpipe to ease future removal. Anti-seize, graphite,etc.? Old pipe new muffler.
 
I've been using this for high-temp applications. It's really nasty, use gloves! Haven't had to take much apart yet so I don't know how it'll work over time, but it's supposed to be good stuff. For other applications, they also have a copper-based anti-seize; I have both.

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I have not been using anything on my Sutton exhaust. The tailpipe comes off every time I remove the bottom cowl.
 
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