Easy Muffler Shroud

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Muffler shroud
Muffler shroud

This is an easy way to make a mold for a muffler shroud layup.

I pegged a board which I clamped to the table of my band saw. Using 2-inch blue construction foam I cut square pieces which I mounted on the peg and pivoted the pieces about the peg through the blade ending up with a stack of foam discs. A bit of glue and I had a cylinder around which I could do layups to form a U-shaped form.

Muffler shroud form
The form

Dissolve the foam with lacquer thinner, cut the layup to shape and bond to the fairing over a precut opening which allows the fairing to be mounted over the muffler.

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Layers of cloth and resin secure the shroud which is then ready for finishing.

My muffler is the Powerflow four-into-one unit built for the GlaStar.

I haven’t flown yet, but based on comments from builders, the Powerflow exhaust is supposed to have noticeable performance improvements for the O-320 Lycomings.

Muffler hanger
Muffler hanger
Muffler mount
Muffler mount

Muffler shroud Muffler shroud Muffler shroud Muffler shroud Muffler shroud

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