Fox 35 Broken Muffler Ear

[Harold Brewer]

Unfortunately, I just broke off a muffler ear on a good running Fox 35.  Does anyone know of a good source for
a muffler clamp for my engine?


Brew

 

[Dan McEntee]

   If you find some of those skinny hose clamps, pick one long enough for the job, cut it in half, and attach it to either side of the muffler. Then use the worm drive to hold it to the engine. Just don't get real ham handed on the screw driver, or you will distort the case and pinch  the cylinder. Another method is to use a strong spring to hold it on, or a bale type of retainer made from music wire. Some one did a real nice photo presentation of how to make home made mufflers using this method that was in the engine forums. Check that out. If you know some one with a TIG welder and they are up to the task, a lump of metal can be welded on to the case and a new ear formed. Also, some have JB-Welded an piece of tubing, brass or aluminum, to the side of the exhaust stack and case. This is best done when the engine still has both mounting ears. I have done all of the above successfully, with the exception of the wire bale, which I will try at the next opportunity.
   Good luck with it,
   Dan McEntee

[John Rist]

Check eBay.  as time goes by a cheep fox 35 with muffler ears may show up. Buy it for the case.

[eric rule]

Had same thing happen to me. Used JB Weld to create new ear. Make sure you clean the crank case well before attempting this repair. I had to use chemical cleaning plus physical cleaning (wire brush) to get all of the lube residue out of the aluminum casting. As an alternative you can create a muffler clamp using some 1/16 X 1/4 brass (from K&S Metal rack in you local hobby shop. Just use pliers to make the bends and the back of the crank case to get the correct bend. Drill 1/8" holes for the bolts to pass through and it will work great.

[Larry Renger]

my dermatologist suggests full brim hats and sunscreen to protect ears!