Brett,
Please tell why&how they did not work.
I must say that I have not used Stalkers myself, but I have flown thousands of flights with Retro engines, they have a slip fit muffler mounting, sealed with an O-ring. Very little problems. And now with our own engine with similar construction, allready over 1000 flights sans problems.
But I agree that not all Stalkers have got it right; some have a "hard" muffler mounting, bolted directly to case and some have a single big thread. In my opinion that's asking for trouble. It's important that the silencer can float without a hard connection to the engine, and also have a flexible mounting in the rear end of muffler.
By the way, one good trick is to wrap 1-2 layers of thin Teflon (for plumbing) tape over and under the O-ring. It protects the ring from burning and getting stuck in the aluminium surfaces.
Only modification that I will make in our new engine is to have 2 O-rings instead of one. It should be a little more forgiving in use. But if the fit geometry is correct and parts well prepared, one ring is just fine, too.
Lauri