Hi Jean
If you are going to weld your muffler:
I owned a 1948 Cessna 170 with a 6 cylinder C-145 (pretty much same motor as a
O-300) with pancake mufflers. Repairing cracks was an ongoing task as was unable
to find new ones.
Using a Hobart TRT250 TIG welder, I found better results using Inconel 600
safety
wire as the welding rod as compared to using various stainless steel rods.
I am not sure what material your muffler is made out of, but if its stainless,
hard and brittle from being work hardened/exposed to carbon/heat/pounding and
interior is somewhat thinning/eroded, don't think you could do much better than:
cleaning surface as best you can getting down to shiny metal, purging interior
with argon and TIG welding with Inconel 600 safety wire where you do not make
an abrupt start or stop, but instead weld a gentle Y to all start and stops
where
end of Y fades to almost no penetration. The later step helped not cause stress
risers and subsequent cracking.
Good luck
Ron Parigoris
Visit - www.EuropaOwners.org
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