Hi Frank;
I sent you some pics from my phone of the modified muffler along side a stock unit. For those that never read my posts, like the ones in this thread, #6 and #8, I have a brand new (at that time) Brodak .25. I mounted it on a fairly light Ringmaster after careful break in per instructions, and no matter what prop I put on it I could not get enough power out of that engine to competently fly the old time pattern. I had a LA.25 on the same model as a comparison. I tried every prop in the book. The engine did not run bad, it just didn't make any power. It would go where ever you needled it, but would not make enough power to pull your hat off your head. It was like the proverbial Eddy Murphy "banana in your tail pipe!"
I commented on it on Stuka Stunt and on here I believe at that time, and I got a message from Tom Hampshire to send him the engine. I had already examined the engine pretty closely and could not see anything obvious, so I marked up all the internals very subtly, and sent it off to him. A few weeks later I got it back with the muffler modified and a nice note from Tom explaining that the muffler, although the same as on the B-.40, was a bit restrictive, and had some before and after RPM data to accompany it. I put the engine back on the airplane and it was like a different engine, but I could see all of my markings on it. In fact I don't think he touched the engine at all, just machined a new , straight through back end with a bigger stinger, cut the back end off the muffler, and pressed the new back end on. The engine didn't sound any louder either. It would still needle fine, and use about the same amount of fuel. That was one of the things that bugged me about it at first, was that it was using fuel, about the same as a LA.25.
I made my self a copy of the muffler from a spare stock Brodak muffler and tried it on the Brodak .40 that is in my Twisted Shark model, which has a early run B-.40 that has been an excellent engine from the beginning, with a good ability to needle where ever I wanted, good power to pull a high 40's ounce airplane, and a nice , subtle break in the maneuvers. With the more open muffler, it had a break that was explosive! It seemed like the model doubled in speed. I didn't try to tame it in any way, as the answer was to simply put the stock muffler back on, and it was back to it's old self. So, there is something to the muffler being restrictive. I haven't tried just cutting off the stinger on a stock muffler and opening up the hole to around 1/2", but it is something to consider. I don't think you here much about the experience that Frank and I have had because it seems like most guys use these for racing and don't use the muffler. That is why I had an easy time of finding a muffler when Brodak didn't have any to sell.
So Frank is not the only one to experience this, but I have no idea how to explain it, but opening up the exhaust does help it quite a bit. And if you look down the venturi, you see w hole lot more spray bar than opening, and I bet opening it up .005" or .010" might make a difference also. I might try that some day just to see what happens with the stock muffler.
Type at you later,
Dan McEntee