Fabricating Johnson A25 Muffler

[chris-p]

Any tips/tricks advice when doing this? I have an A 25 missing the sheet metal muffler, so plan on simply making one. Gauge of metal, and type required would be great to know.

[steveh]

This site gives instructions:

http://www.oddjobmotors.com/tt3_johnson … uffler.htm

[lotec]

The Tech Tip on my site is only about how to make the inner muffler. I usually try Doug Penn when I need the outer muffler. Inless someting has changed, its one of those cases where buying one is a lot cheaper than making one!

[chris-p]

That is great thanks.

The outer muffler I should be able to easily fabricate as well out of sheet metal and rivets. Was it brass?

[wedgie]

The one I have is copper I think. I will have a look when I get home

[bobprock4200]

Look for a section of copper downspout if you can find it. It may or may not be the right dimension, but you can always make it smaller. Anything copper right now is crazy expensive though.

[chris-p]

Ok thanks. I do sheet metal fabrication, so will try some 0.50 copper sheeting and fab one up, and fab up a new inner piece as well. Will see how it goes. Probably easier than polishing and getting the dents out of an old one!

[chris-p]

quote Bob Prock:

Look for a section of copper downspout if you can find it. It may or may not be the right dimension, but you can always make it smaller. Anything copper right now is crazy expensive though.

No kidding!

Believe it or not, Hong Kong or China is the cheapest spot to get the flat stock that I know of, with free shipping. You can get enough to do a muffler for likely under 10 bucks. Buy a few blind copper rivets and away you go. That’s my plan anyways, Ill post some pics of how it looks when Im done.

[Goman]

Dennis Trevathan makes them and other parts for the A models. Nice stuff.
dtrev@comcast.net

[Author]

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