Is there anyone who makes an STC'D tuned exhaust for Maules? I've searched but haven't found any yet.

Thanks!

Power Flow offered to make a system for Maules but apparently didn't get the minimum quantity of purchase commitments to proceed any further. Here's a video of the prototype:

https://www.youtube.com/watch?v=RIZiadtAntU

I had been involved with Dane Wagner, Leading Edge Exhaust, since January 2016 in developing a LEES system for the IO-540 Maules. Unfortunately, he unexpectedly passed away in December. He was pretty much running a one man show, so the new exhaust development has obviously halted.

He had gotten the first system designed, built and made it through dyno testing and I believe got the CMM drawings done. It is a really sweet system with headers and his collector. He used two different mufflers for the dyno testing against stock exhaust. One made 11.1 hp and 20 lb.ft. more torque over stock. The other was 16.8 hp and 31 lb.ft. over stock. The final muffler choice was going to depend on which would pass noise requirements. I believe he was down to noise testing/flight testing and finishing up paper work for the STC.

He was only going to make a system for the fuel injected models, as he didn't want to go through all the carb heat and flight testing for the carb models. About half way through this new development and related frustrations, he reassured me that this would be his last new project.

I talked to Dane Jr about a month ago and everything was on hold as they try to sort everything out and seek a direction. This project is so close, yet so far away...lacking FAA approval. Hopefully someone can pick up Dane's business and run with it. I believe he was about ready to retire and was actively looking for a buyer for his business.

RWM wrote:I had been involved with Dane Wagner, Leading Edge Exhaust, since January 2016 in developing a LEES system for the IO-540 Maules. Unfortunately, unexpectedly passed away in December. He was pretty much running a one man show, so the new exhaust development has obviously halted.

He had gotten the first system designed, built and made it through dyno testing and I believe got the CMM drawings done. It is a really sweet system with headers and his collector. He used two different mufflers for the dyno testing against stock exhaust. One made 11.1 hp and 20 lb.ft. more torque over stock. The other was 16.8 hp and 31 lb.ft. over stock. The final muffler choice was going to depend on which would pass noise requirements. I believe he was down to noise testing/flight testing and finishing up paper work for the STC.

He was only going to make a system for the fuel injected models, as he didn't want to go through all the carb heat and flight testing for the carb models. About half way through this new development and related frustrations, he reassured me that this would be his last new project.

I talked to Dane Jr about a month ago and everything was on hold as they try to sort everything out and seek a direction. This project is so close, yet so far away...lacking FAA approval. Hopefully someone can pick up Dane's business and run with it. I believe he was about ready to retire and was actively looking for a buyer for his business.

Ya it's too bad about Dane. It sounds like Dane Jr wants to take it over, but everything is still tied up in probate. I have Canadas first LEE'S on a Supercub and it is cracked. Dane had a modified design that fixed this problem, but noone but him can do it...

Thanks for the responses thus far. The search continues!

A all new design is what we need.

My O-540 is on 2 complete Maule systems, 4 Maule flame tubes. Then I went to a system for Tims Aircraft. Tim's system is built by Custom Aircraft parts in El Cajon, Ca.

It is a basic copy of the Maule system with several improvements. I have burned out one flame tube and right now I am waiting for a complete muffler for the pilot side. The outer can has a heat bulge and the flame tube is perfect??

I started out cruising at 50* ROP. Over the years I have run more and more rich. I'm now at 100* ROP which is close to 1400* EGT in 12 years I have put 1850 hours on Tango Lima.

I talked to Matt and Clinton at Custom Aircraft. The best answer I have heard after 12 years is don't flog the 540 so hard at take off at sea level. I usual just go WOT, balls to the wall. I'm going to try pulling it back to 25" MP unless I need WOT. Bottom line, it is a poor design that requires regular maintenance.

Cheers...Rob