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Help: cracked muffler

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jeanphilippeneel(at)yahoo
Guest

Posted: Fri Jul 31, 2009 9:38 pm Post subject: Help: cracked muffler

Hi all

My rotax 912 has been flying for 1087h. To day I discover a crack between the mufler and the terminal exhaust pipe (see joined photos) .

 I think I have to change all the exhaust system. 

I ordered immediatly all the system to Europa, but I am afraid they were on holidays for one month.

So I call for help the Europa community:

If some body has a complete exhaust system (mufler+pipes) not yet fitted on his europa, please contact me to know if it will be possible to get me out of the hole.   

Thank you for help

Jean-Philippe Neel

Europa XS Rotax 912 /80Hp

Kit N° 273 F-PSLH

Grenoble-France

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Brian Davies

Joined: 10 Jan 2006
Posts: 124
Location: uk

Posted: Fri Jul 31, 2009 10:53 pm Post subject: Help: cracked muffler

JP,

  

 In view of the location of the crack, I would think a good  welder could repair the exhaust system at least as a temporary  repair.

  

 Regards

 Brian Davies



   From: owner-europa-list-server(at)matronics.com  [mailto:owner-europa-list-server(at)matronics.com] On Behalf Of NEEL Jean  Philippe

Sent: 01 August 2009 06:35

To:  europa-list(at)matronics.com

Subject: Help: cracked  muffler

 

   Hi all

 My rotax 912 has been flying for 1087h. To day I  discover a crack between the mufler and the terminal exhaust pipe (see joined  photos) .

  I think I have to change all the exhaust  system. 

 I ordered immediatly all the system to Europa, but I am  afraid they were on holidays for one month.

 So I  call for help the Europa community:

 If some body has a complete exhaust system  (mufler+pipes) not yet fitted on his europa, please contact me to know if it  will be possible to get me out of the hole.   

 Thank you for help

 



 Jean-Philippe Neel

 Europa XS Rotax 912 /80Hp

 Kit N° 273 F-PSLH

 Grenoble-France

 

 

 

No virus found in this incoming message.

Checked  270.13.38/2274 -  Release Date: 07/31/09 05:58:00

 

   [quote][b]

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grahamsingleton(at)btinte
Guest

Posted: Sat Aug 01, 2009 12:20 am Post subject: Help: cracked muffler

NEEL Jean Philippe wrote:

 	  Quote: 	
		   Hi all

 My rotax 912 has been flying for 1087h. To day I discover a crack 

 between the mufler and the terminal exhaust pipe (see joined photos) .

  I think I have to change all the exhaust system.



Jean-Philippe
	


I think your exhaust was made by Heggemann, Europa Aircraft now buy them 

from CKT Engineering, not quite the same but should fit OK.why not talk 

to them.

Chris Piper is the man to talk to.

<http://www.cktengineering.com/aerospace_exhausts.php>

Graham

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rparigor(at)suffolk.lib.n
Guest

Posted: Sat Aug 01, 2009 2:41 am Post subject: Help: cracked muffler

Hi Jean



If you are going to weld your muffler:



I owned a 1948 Cessna 170 with a 6 cylinder C-145 (pretty much same motor as a O-300) with pancake mufflers. Repairing cracks was an ongoing task as was unable to find new ones.



Using a Hobart TRT250 TIG welder, I found better results using Inconel 600 safety wire as the welding rod as compared to using various stainless steel rods.



I am not sure what material your muffler is made out of, but if its stainless,  hard and brittle from being work hardened/exposed to carbon/heat/pounding and interior is somewhat thinning/eroded, don't think you could do much better than:

cleaning surface as best you can getting down to shiny metal, purging interior with argon and TIG welding with Inconel 600 safety wire where you do not make an abrupt start or stop, but instead weld a gentle Y to all start and stops where end of Y fades to almost no penetration. The later step helped not cause stress risers and subsequent cracking.

Good luck

Ron Parigoris

Visit -  www.EuropaOwners.org

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cjaussi(at)gmail.com
Guest

Posted: Sat Aug 01, 2009 5:53 pm Post subject: Help: cracked muffler

I have a complete mufler system from a europa xl with a 912 engine.  i replaced it with a 914 turbo and needed a different one.  It has less than forty hours on it.  It has a europa mandated repair to see if the screen inside is still attached that has not been done.  Please contact me online direct if you are interested in it.  I am sure the price will be right.  Curtis Jaussi.   cjaussi(at)gmail.com (cjaussi(at)gmail.com)

 

 On Sat, Aug 1, 2009 at 4:42 AM, rparigoris <rparigor(at)suffolk.lib.ny.us (rparigor(at)suffolk.lib.ny.us)> wrote:

 [quote]--> Europa-List message posted by: "rparigoris" <rparigor(at)suffolk.lib.ny.us (rparigor(at)suffolk.lib.ny.us)>

 

Hi Jean



If you are going to weld your muffler:



I owned a 1948 Cessna 170 with a 6 cylinder C-145 (pretty much same motor as a O-300) with pancake mufflers. Repairing cracks was an ongoing task as was unable to find new ones.

 

Using a Hobart TRT250 TIG welder, I found better results using Inconel 600 safety wire as the welding rod as compared to using various stainless steel rods.



I am not sure what material your muffler is made out of, but if its stainless,  hard and brittle from being work hardened/exposed to carbon/heat/pounding and interior is somewhat thinning/eroded, don't think you could do much better than:

 cleaning surface as best you can getting down to shiny metal, purging interior with argon and TIG welding with Inconel 600 safety wire where you do not make an abrupt start or stop, but instead weld a gentle Y to all start and stops where end of Y fades to almost no penetration. The later step helped not cause stress risers and subsequent cracking.

 



Good luck

Ron Parigoris

Visit -  www.EuropaOwners.org

  

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[b]

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rampil

Joined: 04 May 2007
Posts: 870

Posted: Sat Aug 01, 2009 6:20 pm Post subject: Re: Help: cracked muffler

Hello Jean-Philippe,



I imagine that in Grenoble there are several automotive exhaust

repair and custom build shops.  I had my original exhaust repair-

welded twice in different locations before ultimately replacing the whole

system.



You did not mention the vintage of your system, but like the current

vintage, it is probably a stainless system and best welded with a TIG

system - in my opinion no job for a beginner. Have an experienced

shop do it.



Next, you should try to determine why this crack occured.  Do you have

a long final exhaust pipe? Is the exhaust banging against some part

of the cowl or other structure?



Good Luck,



Ira

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_________________
Ira N224XS

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