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exhaust system modification

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Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Fri Jun 08, 2012 4:19 pm Post subject: exhaust system modification

Here is a shot of my new exhaust system, with Burn's Stainless 4- 

into-1 collector and megaphone, if anybody is interested.



Just today I installed heat muffs on both sides to allow for cabin  

heat, and carb (TBI) heat. Both work well, with the carb heat side  

increasing the inlet air temp from about 90 deg. F., to 175 deg F. in  

about 15 seconds. The sound is pretty mellow, too. : )



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062

Prince prop 64 x 30, P-tip

Electroair direct-fire ignition system

Rotec TBI-40 injection (sleeved to 36mm)

Status: flying with 1279 hrs... (since 3-27-2006)

100_1294.jpg

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_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

Jim McCormick

Joined: 19 Mar 2007
Posts: 18
Location: Fresno, CA

Posted: Fri Jun 08, 2012 5:16 pm Post subject: exhaust system modification

Hey Lynn



Nice Job!

Jim McCormick

Jabiru Pacific LLC

255 W Fallbrook Suite 202B

Fresno, Ca 93722

559-431-1701

jim(at)jabirupacific.com

http://www.jabirupacific.com



On 6/8/12 5:14 PM, "Lynn Matteson" <lynnmatt(at)jps.net> wrote:



 	  Quote: 	
		   Here is a shot of my new exhaust system, with Burn's Stainless 4-

 into-1 collector and megaphone, if anybody is interested.

 

 

 Just today I installed heat muffs on both sides to allow for cabin

 heat, and carb (TBI) heat. Both work well, with the carb heat side

 increasing the inlet air temp from about 90 deg. F., to 175 deg F. in

 about 15 seconds. The sound is pretty mellow, too. : )

 

 Lynn Matteson

 Kitfox IV Speedster, taildragger

 Jabiru 2200, #2062

 Prince prop 64 x 30, P-tip

 Electroair direct-fire ignition system

 Rotec TBI-40 injection (sleeved to 36mm)

 Status: flying with 1279 hrs... (since 3-27-2006)

dons701

Joined: 22 May 2009
Posts: 80
Location: Hershey, PA

Posted: Fri Jun 08, 2012 6:20 pm Post subject: Re: exhaust system modification

Hi Lynn, gotta ask. Any noticeable changes in power??

_________________
Zenith 701 #76120
Jabiru 2200A #2456 95 hours
Sensenich Wood 64-PJ-36 Prop

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Fri Jun 08, 2012 6:48 pm Post subject: exhaust system modification

Thanks, Jim....I'm only responsible for the pipes leading down to the  

collector, but overall, I think it looks pretty good.

Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062

Prince prop 64 x 30, P-tip

Electroair direct-fire ignition system

Rotec TBI-40 injection (sleeved to 36mm)

Status: flying with 1279 hrs... (since 3-27-2006)

On Jun 8, 2012, at 9:15 PM, jim wrote:



 	  Quote: 	
		   



 Hey Lynn



 Nice Job!

 Jim McCormick

 Jabiru Pacific LLC

 255 W Fallbrook Suite 202B

 Fresno, Ca 93722

 559-431-1701

 jim(at)jabirupacific.com

 http://www.jabirupacific.com



 On 6/8/12 5:14 PM, "Lynn Matteson" <lynnmatt(at)jps.net> wrote:



> Here is a shot of my new exhaust system, with Burn's Stainless 4-

> into-1 collector and megaphone, if anybody is interested.

> Just today I installed heat muffs on both sides to allow for cabin

> heat, and carb (TBI) heat. Both work well, with the carb heat side

> increasing the inlet air temp from about 90 deg. F., to 175 deg F. in

> about 15 seconds. The sound is pretty mellow, too. : )

>

> Lynn Matteson

> Kitfox IV Speedster, taildragger

> Jabiru 2200, #2062

> Prince prop 64 x 30, P-tip

> Electroair direct-fire ignition system

> Rotec TBI-40 injection (sleeved to 36mm)

> Status: flying with 1279 hrs... (since 3-27-2006)

>

>

_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Fri Jun 08, 2012 7:12 pm Post subject: exhaust system modification

Hi Don-

It's really hard to say whether the power was improved or not, just  

because of the very nature of flight....with race cars, you can  

always compare lap times, 1/4 mile times, etc., but with the  

varieties of flight conditions, I can't tell for sure if any more  

power is being produced. My primary reason for doing this job was  

inspiration that I got when reading the April 2012 issue of Kitplanes  

magazine about making headers for a 540 Lycoming, I think it was.  

Also, I had two straight pipes before and it was pretty noisy, and I  

wanted to try to get the sound a bit more controlled.



To order the collector, I had to supply Burns with cam timing, valve  

lift and size, port size, engine size, primary exhaust diameter,  

desired rpm where the engine will run, etc., and they run those specs  

through their design-X program and give you the recommended specs for  

the collector and the diameter and length of the megaphone and the  

reverse cone on the end. The reverse cone is said to extend the  

torque range. I have to admit that I did not make the primaries the  

exact length that I should have. To do so would have taken too much  

time and effort.....I may do so in the future. This will require  

making the original #3 and #4 pipe the same length as the original #1  

and #2 pipes which are currently a bit longer. This means snaking  

some tubing in a roundabout way so that all the primaries will be the  

same length, and then the system will be tuned properly, and I'll get  

the most benefit from the collector and megaphone. But I'm happy with  

the system for now, and when I get bored, I'll fire up the TIG and  

modify those #3 and 4 pipes.



Incidentally, I tried "back-purging" for the first time on this  

job...stainless steel welding looks like crap without it....and was  

amazed at how good the welds that I did came out. Burns has good  

information on their website as to how to do this.



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062

Prince prop 64 x 30, P-tip

Electroair direct-fire ignition system

Rotec TBI-40 injection (sleeved to 36mm)

Status: flying with 1279 hrs... (since 3-27-2006)





On Jun 8, 2012, at 10:20 PM, dons701 wrote:



 	  Quote: 	
		   

 <burdon1(at)comcast.net>



 Hi Lynn, gotta ask. Any noticeable changes in power??



 --------

 Zenith 701 #76120

 Jabiru 2200A #2456  95 hours

 Sensenich Wood 64-PJ-36 Prop





 Read this topic online here:



 http://forums.matronics.com/viewtopic.php?p=375070#375070

_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

checkpoint2(at)comcast.ne
Guest

Posted: Sat Jun 09, 2012 6:44 am Post subject: exhaust system modification

Hey Lynn That is a positive move.  I extended the pipes from 

the two into one junction and added approximately 24 inches of extension

each side. I used motorcycle tabs and springs to support the additional 

weight.  It is not tuned but it's not too loud, and no cracks in about a 100

hours.   I like your idea though. N 380 BH Alpi Pioneer Jabiru 2200.



--

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Sat Jun 09, 2012 9:30 am Post subject: exhaust system modification

Thanks, Bob. The other reason that I did not try to "tune" the  

primary pipes to the suggested 32" was because of the problem of  

wrapping a heat muff around the pair of pipes on each side. If I had  

added some "extender bends" to the rear pipes, the heat muff would  

have been the size of a 55-gallon barrel. Here's a picture of the  

heat muffs prior to welding on the in and out tubes, which are now  

finished and installed:



Now that I look at the picture again, the heat muffs will stay the  

same regardless of what I do to the Jabiru original rear primary  

pipes, as long as I do it before the slip-joint....Duhhh!! (sometimes  

I engage the fingers before the brain)  Let me start again....the  

main reason that I did not make all pipes the same length was to be  

able to expedite the job, and get back to flying.



By the way, Burns' Stainless sells the tabs and springs (called  

beehive springs, I think) and also sells stainless steel tabs which  

sit side-by-side on the to-be-connected pipes and are held together  

by a bolt.



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062

Prince prop 64 x 30, P-tip

Electroair direct-fire ignition system

Rotec TBI-40 injection (sleeved to 36mm)

Status: flying with 1280 hrs... (since 3-27-2006)





On Jun 9, 2012, at 10:44 AM, Bob Haas wrote:



 	  Quote: 	
		   

 <checkpoint2(at)comcast.net>



                Hey Lynn That is a positive move.  I extended the  

 pipes from the two into one junction and added approximately 24  

 inches of extension

 each side. I used motorcycle tabs and springs to support the  

 additional weight.  It is not tuned but it's not too loud, and no  

 cracks in about a 100

 hours.   I like your idea though. N 380 BH Alpi Pioneer Jabiru 2200.

100_1296.jpg

Description:

Filesize:

401.09 KB

Viewed:

14247 Time(s)

_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Sat Jun 09, 2012 9:33 am Post subject: exhaust system modification

Thanks, Bob. The other reason that I did not try to "tune" the  

primary pipes to the suggested 32" was because of the problem of  

wrapping a heat muff around the pair of pipes on each side. If I had  

added some "extender bends" to the rear pipes, the heat muff would  

have been the size of a 55-gallon barrel. Here's a picture of the  

heat muffs prior to welding on the in and out tubes, which are now  

finished and installed:



Now that I look at the picture again, the heat muffs will stay the  

same regardless of what I do to the Jabiru original rear primary  

pipes, as long as I do it before the slip-joint....Duhhh!! (sometimes  

I engage the fingers before the brain)  Let me start again....the  

main reason that I did not make all pipes the same length was to be  

able to expedite the job, and get back to flying.



By the way, Burns' Stainless sells the tabs and springs (called  

beehive springs, I think) and also sells stainless steel tabs which  

sit side-by-side on the to-be-connected pipes and are held together  

by a bolt.



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062

Prince prop 64 x 30, P-tip

Electroair direct-fire ignition system

Rotec TBI-40 injection (sleeved to 36mm)

Status: flying with 1280 hrs... (since 3-27-2006)





On Jun 9, 2012, at 10:44 AM, Bob Haas wrote:



 	  Quote: 	
		   

 <checkpoint2(at)comcast.net>



                Hey Lynn That is a positive move.  I extended the  

 pipes from the two into one junction and added approximately 24  

 inches of extension

 each side. I used motorcycle tabs and springs to support the  

 additional weight.  It is not tuned but it's not too loud, and no  

 cracks in about a 100

 hours.   I like your idea though. N 380 BH Alpi Pioneer Jabiru 2200.

100_1296.jpg

Description:

Filesize:

401.09 KB

Viewed:

14247 Time(s)

_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

checkpoint2(at)comcast.ne
Guest

Posted: Tue Jun 12, 2012 10:43 am Post subject: exhaust system modification

Lynn,  Makes sense to me.  Right now I would have to 15000 ft. 

or higher to justify a heat muff. My aircraft only flies in the confines of 

the

Florida Peninsula, no heat required.  Bob Haas.



--

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Wed Jun 13, 2012 4:50 am Post subject: exhaust system modification

I gotcha, Bob....this morning that heat muff felt really good in the  

46 degree morning air....quite a change from Mondays' 90!



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062

Prince prop 64 x 30, P-tip

Electroair direct-fire ignition system

Rotec TBI-40 injection (sleeved to 36mm)

Status: flying with 1284 hrs... (since 3-27-2006)

do not archive



On Jun 12, 2012, at 2:41 PM, Bob Haas wrote:



[quote] 

 <checkpoint2(at)comcast.net>



            Lynn,  Makes sense to me.  Right now I would have to  

 15000 ft. or higher to justify a heat muff. My aircraft only flies  

 in the confines of the

 Florida Peninsula, no heat required.  Bob Haas.



 --

_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

carlmeek(at)gmail.com
Guest

Posted: Wed Jun 13, 2012 4:58 am Post subject: exhaust system modification

While are on the topic of heat muffs, does anyone know where I can buy one

(or two!) for a Jabiru 3300?

I've not found a supplier who has them.



Thanks,

-Carl.



On 13/06/2012 13:49, "Lynn Matteson" <lynnmatt(at)jps.net> wrote:



[quote]



I gotcha, Bob....this morning that heat muff felt really good in the

46 degree morning air....quite a change from Mondays' 90!



Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062

Prince prop 64 x 30, P-tip

Electroair direct-fire ignition system

Rotec TBI-40 injection (sleeved to 36mm)

Status: flying with 1284 hrs... (since 3-27-2006)

do not archive



On Jun 12, 2012, at 2:41 PM, Bob Haas wrote:



> 

> <checkpoint2(at)comcast.net>

>

>            Lynn,  Makes sense to me.  Right now I would have to

> 15000 ft. or higher to justify a heat muff. My aircraft only flies

> in the confines of the

> Florida Peninsula, no heat required.  Bob Haas.

>

> --

dwwilt

Joined: 06 Dec 2010
Posts: 192

Posted: Wed Jun 13, 2012 5:01 am Post subject: exhaust system modification

I would think that you could get one from the dealer.

 

      

   Dennis

   N616DW (Arion Lightning S/N 132)

 

 

 

   --

_________________
Dennis

mhubel

Joined: 05 Sep 2009
Posts: 141

Posted: Wed Jun 13, 2012 5:28 am Post subject: exhaust system modification

Carl,

     If you want one which will fit on the pipe coming out of the 

muffler instead of one that goes on the muffler and spans a possibly 

leaky weld (don't ask), you can contact:



sales(at)aircraftexhaust.net



They can supply one of almost any size.



I now have one which I took off the muffler but can't really recommend 

it for anyone.

On 06/13/2012 8:57 AM, Carl Meek wrote:

[quote] 



 While are on the topic of heat muffs, does anyone know where I can buy one

 (or two!) for a Jabiru 3300?

 I've not found a supplier who has them.



 Thanks,

 -Carl.



 On 13/06/2012 13:49, "Lynn Matteson"<lynnmatt(at)jps.net>  wrote:



> 

>

> I gotcha, Bob....this morning that heat muff felt really good in the

> 46 degree morning air....quite a change from Mondays' 90!

>

> Lynn Matteson

> Kitfox IV Speedster, taildragger

> Jabiru 2200, #2062

> Prince prop 64 x 30, P-tip

> Electroair direct-fire ignition system

> Rotec TBI-40 injection (sleeved to 36mm)

> Status: flying with 1284 hrs... (since 3-27-2006)

> do not archive

>

> On Jun 12, 2012, at 2:41 PM, Bob Haas wrote:

>

>> 

>> <checkpoint2(at)comcast.net>

>>

>>             Lynn,  Makes sense to me.  Right now I would have to

>> 15000 ft. or higher to justify a heat muff. My aircraft only flies

>> in the confines of the

>> Florida Peninsula, no heat required.  Bob Haas.

>>

>> --

_________________
Mark Hubelbank
N708HU
CH601XL
Jabiru 3300
Rotec TBI 40-3 carb
Sensenich ground adj prop.
240 hr TAF
Pictures at photo.hubbles.com

Lynn Matteson

Joined: 10 Jan 2006
Posts: 2778
Location: Grass Lake, Michigan

Posted: Thu Jun 14, 2012 2:42 am Post subject: exhaust system modification

I built a pair of muffs for a friends' 3300 in his Waiex. I made the  

front "bulkhead" for the muff behind all the factory welds so no  

chance of a leaky weld admitting CO into the cabin. Making that  

bulkhead was a BITCH! It involved cutting a 3-lobe hole into a piece  

of stainless steel, and cutting and fitting, cutting and fitting  

until it finally fit. I don't know how well they worked, because  

another person suggested that they might be the reason that his  

engine...brand new and not broken in yet... was overheating (the jury  

is still out on that call), so he took them off. But here are  

pictures of what I did.

Lynn Matteson

Kitfox IV Speedster, taildragger

Jabiru 2200, #2062

Prince prop 64 x 30, P-tip

Electroair direct-fire ignition system

Rotec TBI-40 injection (sleeved to 36mm)

Status: flying with 1285 hrs... (since 3-27-2006)

On Jun 13, 2012, at 8:57 AM, Carl Meek wrote:



 	  Quote: 	
		   

 <carlmeek(at)gmail.com>



 While are on the topic of heat muffs, does anyone know where I can  

 buy one

 (or two!) for a Jabiru 3300?

 I've not found a supplier who has them.



 Thanks,

 -Carl.

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_________________
Lynn
Kitfox IV-Jabiru 2200
N369LM

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