Randy,
I have perhaps 10 flights on the muffler before Winter set in. I did the engine break-in (1 to 2 hours) with the previous (identical) muffler with no noticeable degradation of the muffler. However, the header failed near the mounting flange after a couple flights. I then made another, identical unit with the header separated from the muffler with a silicone tube (like a tuned pipe setup). I think that cured the problem.
Not having a sound pressure meter I can only give you a relative noise level. I think it is slightly louder than a Retro 60, which is fairly quiet. During the break-in period, I posted a video of a bench run of this engine. There was considerable interest in that, so I posted the first full pattern as well. You can hear the engine run pretty well during the pattern:
Fred