Backcountry Pilot • Lycoming O-540 making metal+2012 Annual update

Lycoming O-540 making metal+2012 Annual update

Lycoming, Continental, Hartzell, McCauley, or any broad spectrum drive system component used on multiple type.
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Re: Lycoming O-540 making metal+2012 Annual update

Yeah, that Cabella's a unique revenue gravity. I can't drive near it without sprinkling money there.
Chaz
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Re: Lycoming O-540 making metal+2012 Annual update

Must be something in the "air" so to speak. I got to buy a friggin' muffler today too. The other side will probably go next week.
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Re: Lycoming O-540 making metal+2012 Annual update

gbflyer wrote:Must be something in the "air" so to speak. I got to buy a friggin' muffler today too. The other side will probably go next week.


How much is a Cessna muffler?
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Re: Lycoming O-540 making metal+2012 Annual update

Here's the best you can get in my opinion! Not that that means much!!
GT

http://www.wemakeyoufly.com/main_products.asp

Best Pipes and Warranty in the Business!
Sunday, 12 March 2006
How many times have you asked yourself, Why can’t they build exhaust systems that last as long as engine TBO? The long awaited answer you have been searching for is finally here…
Leading Edge Exhaust Systems, LLC, (LEES) located in Anchorage Alaska has solved the inherent problems that have plagued the stock OEM exhaust collectors since their inception. Approximately 13 years ago, Dane Wagner, Sr., or D1 as he is known in the shop, designed and built a new exhaust collector that was unique enough to receive a United States Patent. The new design eliminated the standard stamped out half designs that have inherent internal turbulence that reduces product life as well as increases the back pressure thus reducing available power.



What led to this design was Wagner’s involvement with his FAA approved welding and non-destructive testing facility that he started in the 80’s. That was over 20 years ago and now LEES has one of the most modern fabrication shops in Alaska. The original shop repaired many hundreds of Cessna 206/207 exhaust collectors that are so prevalent in Alaska. The popular Cessna 206/207 series aircraft are used for Air Taxi, Flight Seeing, US Mail, valuable freight hauling to isolated villages and also includes very remote big game hunting and trophy class fishing. These are some of the high priority necessities required to build a successful flying business in Alaska. All of these very important business income sources come with some very big profit consuming expenses like; extremely costly downtime delays; having to get exhaust system removed and subsequently repaired by an approved facility in a timely and cost effective manner and that’s not always possible.
Having done literally many thousands of repairs was the impetus that brought this new unique design to D1’s attention and that is when the “Best Pipes and Warranty in the Business” trademark was born!! The trademark is a good explanation why 75% of the Air Taxi operators in Alaska use LEES’ pipes. D1 eliminated the internal back pressure turbulence by mandrel bending precision, 40% thicker, equal length, 321 stainless steel primary tubes that all exit in the same direction. The spent exhaust gases merge in the patented 3-1 collector and then funnel through the integral venturi that speeds things up. From there, they exit through the ball joint into the muffler and finally leave the scene by way of the tail pipe. This radically new design reduced back pressure by approximately 50% which lets the engine operate more efficiently like it was originally designed to do. By reducing and balancing the back pressure the engine produces better power with greater fuel efficiency. You can expect approximately 10 more horsepower utilizing LEES’ pipes. LEES has a Canadian distributor that claims they have a customer that had his own dyno test performed and pulled nearly 15 more Hp.
Having more power is great, but more important than that is having an exhaust system that has a higher TBO than the engine. Would you believe LEES pipes have held up through 3 engine TBO’s? It is not uncommon after having accumulated more than 5000 hours of operations to have the original LEES’ collectors rebuilt to like new condition for a fraction of the cost of a new set. Another very important and unique attribute is the 20 year or 2000 hour transferable warranty. The warranty is not only one of a kind but also has proved to be a valuable sales asset. If the aircraft is sold the remaining warranty can be transferred to a new owner. These are a few of the reasons influencing LEES’ opinion they do have the “Best Pipes and Warranty in the Business”. tm
LEES exhaust collectors are direct replacement parts for Cessna 205,206,207 and 210 series aircraft. The Approved Model List can be researched on LEES’s website on the Cessna 205-210 Series Exhaust Collectors’ product page. The current single set price is $2450.00 with no core charge. Ask about LEES’ multi-set or fleet discount.
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Re: Lycoming O-540 making metal+2012 Annual update

$440 from Knisley.

GT, I like that LEE setup too. I think they still use the same old muffler?
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Re: Lycoming O-540 making metal+2012 Annual update

Cessna Mufflers

LEES is starting the FAA approval process for the Cessna 180, 182 & 185 muffler baffle kits. Kits will be approved for sale and installation by other facilities. LEES separate repair station will also install them for a flat rate. LEES is going to offer, what we feel is, the best warranty in the country. Our Cessna US Patented, FAA/PMA approved 205/210 exhaust collectors offers a 2000 hour or 20 year warranty. Muffler baffle warranty will be 1000 hours or 5 years. Other common muffler baffles usually offer 1 year/unlimited hours. One of LEES' customers has a set of the new US Patented 185 muffler baffles installed that presently has 2000 hours on them. LEES experience with muffler baffles has shown that the OEM muffler baffles usually last about 300 to 400 hours. To repair the muffler the entire exhaust system has to be removed, muffler gutted, rebuilt and then reinstalled. Downtime and expense is incurred. LEES say their US Patented, FAA/PMA muffler baffle repair kits will be competitively priced and will far outlast other baffles.

GT
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Re: Lycoming O-540 making metal+2012 Annual update

UPS Tracking says my carburetor will be in Troutdale Friday. So looks like next week back in the air.

Good day
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Re: Lycoming O-540 making metal+2012 Annual update

I too am waiting for parts...Flame Traps and SL 66 bolt kit for my spring gear. Hopefully back up by Friday...but that may just be wishful thinking. [-o<
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Re: Lycoming O-540 making metal+2012 Annual update

CHT are over ridden by EGT regarding the temps in the muffler.
There is an SB to inspect the tailpipe clamps every annual or 100 hrs, which means it is easy to inspect the flame traps/diffusers/baffles on a Maule.
The problem baffles are on the IO and O540s because the two rear exhausts enters the muffler perpendicularly.
It is easy with a diegrinder to remove the tack welds and withdraw the damaged baffle out the tailpipe socket.
Order the new perforated tube baffles WITHOUT the tailpipe socket attached, push into the muffler and tackweld. Voila.
When the EGTs are hot, do not allow over rich mixtures and rapid throttle reduction to cause backfireing.
The baffles should last 400 hours and the mufflers 1000hrs.
Hope that helps.
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Re: Lycoming O-540 making metal+2012 Annual update

Argh, parts did NOT arrive today...so much for 2-day shipping :?

Thanks for the tips, Jeremy. I did order the flame traps without the tailpipe socket like you said.
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Re: Lycoming O-540 making metal+2012 Annual update

Got the Maule back together Saturday the 10th I will bring it home the next decent fly day. New exhaust and carburetor leak fixed. I should be good for the next year!
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Re: Lycoming O-540 making metal+2012 Annual update

Did you catch the new AD on the HA-6 carb that went into effect last wednesday? I got lucky & missed it..

http://www.airweb.faa.gov/Regulatory_and_Guidance_Library/rgAD.nsf/0/5650B8CD2CD80877862579AB00503BA4?OpenDocument
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Re: Lycoming O-540 making metal+2012 Annual update

JDW wrote:Did you catch the new AD on the HA-6 carb that went into effect last wednesday? I got lucky & missed it..

http://www.airweb.faa.gov/Regulatory_and_Guidance_Library/rgAD.nsf/0/5650B8CD2CD80877862579AB00503BA4?OpenDocument

I'll check it. Thanks
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Re: Lycoming O-540 making metal+2012 Annual update

SB- 18 that lists the effected carbs
http://www.msacarbs.com/pdf/SB-18_A%20031511.pdf
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Lycoming O-540 making metal+2012 Annual update

On my way to bring the m7 home
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Re: Lycoming O-540 making metal+2012 Annual update

OregonMaule wrote:On my way to bring the m7 home


to your home or mine? :mrgreen:
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Re: Lycoming O-540 making metal+2012 Annual update

Back home. Went by Pine Hollow, landed the grass at Hood River, 3 grass landings at Cascade Locks. The new exhaust is QUIET!

Turned out to be a good day to fly. Between storms. Boy oh boy am I ready to get some flying in now!!

Cheers
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Re: Lycoming O-540 making metal+2012 Annual update

OregonMaule wrote:3 grass landings at Cascade Locks


I don't remember seeing a grass strip at the Locks, can ya just land on the grass next to the runway there? Bummer I never stopped in there then!
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Lycoming O-540 making metal+2012 Annual update

Yep grass parallel to 24. The moles are out of control. The 29 s smash their mounds.
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Re: Lycoming O-540 making metal+2012 Annual update

Arrrgghhh! Just out of annual, compressions on my IO-540 = 79, 76, 79, 77, 78, 78...not too shabby, right? :o

[-X then I got the oil analysis back...showing a little more metal than the previous two (nothing showing in the filter, yet).

I'm thinking a borescope is in order... [-o<
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