Tom Baker Posted October 6, 2022 Report Share Posted October 6, 2022 I'm doing a rubber replacement, and I always check the mufflers. I found one today with two leaks, both which would have went directly into the heat muff. I have 4 plugs that are made from https://www.aircraftspruce.com/catalog/eppages/pushrodseals.php and a bolt, nut, and two washers. You can tighten the nut to tighten the plug in the hole. To connect to the tailpipe I use https://www.aircraftspruce.com/catalog/eppages/intakehoses_08-03700.php coupled to my shop-vac blowing air. Use what ever connection works best for your shop-vac. I just used what I had laying around. Spray soapy solution and watch for bubbles. Quote Link to comment Share on other sites More sharing options...
Tom Baker Posted October 6, 2022 Author Report Share Posted October 6, 2022 IMG_1889.MOV IMG_1890.MOV Quote Link to comment Share on other sites More sharing options...
FlyingMonkey Posted October 6, 2022 Report Share Posted October 6, 2022 I had to have a hairline crack welded on mine last year. Quote Link to comment Share on other sites More sharing options...
Madhatter Posted October 6, 2022 Report Share Posted October 6, 2022 I have been warning about that for years. FD has a defect in welding their muffler heat muff stand-off rings which causes cracks in the muffler. I suspect that most CT's have cracks over 800 hrs. The only thing saving people from CO issues is the large amount of air leaks in the cockpit. There is no difference between LSA and certified when it comes to this. It is a huge issue in certified with a lot of AD'S. Most good shops (good for Tom) pressure check mufflers at annual now, it's a huge liability issue for them. Quote Link to comment Share on other sites More sharing options...
Anticept Posted October 6, 2022 Report Share Posted October 6, 2022 We're discovering them rather often too. Please remember to fill out service difficulty reports. Quote Link to comment Share on other sites More sharing options...
procharger Posted November 27, 2022 Report Share Posted November 27, 2022 (edited) i Had about 3 inch hole blow out in mine couple years ago never heard any difference in sound it warped the cowl a little bit from heat. happened at around 1500 HRS Edited November 27, 2022 by procharger miss spell word Quote Link to comment Share on other sites More sharing options...
Madhatter Posted November 27, 2022 Report Share Posted November 27, 2022 Almost all aircraft get about 1000 hrs or less when problems start. Be ready for sticker shock from FD. If you buy from Rotax you still have to weld the heat muff rings on. You can only patch mufflers for so long, if the flame cone fails you can lose power when it blocks the exhaust pipe. There are a lot of airworthiness directives on these issues. Quote Link to comment Share on other sites More sharing options...
Animosity2k Posted December 3, 2022 Report Share Posted December 3, 2022 Are all the areas prone to cracking visible with the cowling on or do I need to remove it and check all the way back to the headers? Quote Link to comment Share on other sites More sharing options...
GrassStripFlyBoy Posted December 3, 2022 Report Share Posted December 3, 2022 Hey Mike - not visible, and even with it off and the shroud is removed, it requires a shop vac to pressurize the muffler and soapy water to expose possible cracks. Servicing exhaust is not hard just takes a bit of time, and the proper materials like stainless anti seize for joints, maybe bending the spring tabs back if things are loose, some new springs are wise too. If you're concerned about it, CO detectors are fairly cheap too. Quote Link to comment Share on other sites More sharing options...
BravoFoxtrot Posted December 3, 2022 Report Share Posted December 3, 2022 I believe the plugs required are about 1-1/4". Could anyone confirm this? Thanks Quote Link to comment Share on other sites More sharing options...
Tom Baker Posted December 3, 2022 Author Report Share Posted December 3, 2022 1 hour ago, BravoFoxtrot said: I believe the plugs required are about 1-1/4". Could anyone confirm this? Thanks That sounds about right. I showed what I use in the first post. It was parts that I had just laying around, but they are not terribly expensive to buy. The one muffler I had come back from repair looked like they had used duct tape to seal it off. Quote Link to comment Share on other sites More sharing options...
BravoFoxtrot Posted December 4, 2022 Report Share Posted December 4, 2022 Ok, thanks! Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.