Just wanted to share the condition of my PA-22 muffler we replaced this week during annual. This is after 1075 hours in service taken with my boroscope. For those not familiar, on many classic Pipers after a muffler hits 950 hours it requires inspection every 50 hours. From the internal condition of my muffler I can see why. Warped and cracked metal on the internal flame cone of the right side. The external metal and ends were still in good shape, so probably not a threat to the safety of flight and/or CO poisoning just yet, but glad I have the wire bail on the tailpipe as chunks of metal could clog the tailpipe without it. Anyway they are a real pain to get in and out.

2015-03-25-19-28-24 by scottf/url], on Flickr

[url=https://flic.kr/p/rvDtBd]2015-03-25-19-29-58 by scottf, on Flickr

2015-03-25-19-30-30 by scottf, on Flickr

2015-03-25-19-30-38 by scottf, on Flickr

2015-03-25-19-30-54 by scottf, on Flickr

What brand of muffler was it?

What brand of scope you got? It takes pretty good pictures

Muffler was an Aero Fabricators. The new one we put in is from Knisley Welding. I wonder if there is much difference in durability.

My scope is a wifi scope I picked up on Amazon like this one. Really handy for all sorts of stuff, and talks to an android or apple device over wifi.

scottf wrote: Muffler was an Aero Fabricators. The new one we put in is from Knisley Welding. I wonder if there is much difference in durability.....

Aero Fabricators is a division of Wag Aero. Knisely has a pretty good rep-- not to belittle Wag, but I'm guessing the new one'll be a lot more skookum.

There's a pretty good thread going on supercub.org right now about this. If the flame tube comes apart, it can result in the old "banana in the tailpipe" power loss thing- not good. Not sure if its approved for 22's, but Atlee Dodge apparently sells a muffler without flame tubes for the PA18. It's called the hotrod muffler, don't know of that's just because it's louder or if the straight-through design results in more power.

Yeah I wish I could have gone with the hotrod muffler but unfortunately it is not STC'd for the PA-22 and it didn't sound like there were any plans to do so.

1) field approval
or
2)don't ask, don't tell

Check out Leading Edge Exhaust if you ever have to replace the entire exhaust system.

http://www.wemakeyoufly.com/piper-aircraft-exhaust-systems/piper-pa-2022-150-160-180hp/

You get what you pay for! Knisley or Acorn are built to last.

Quickdraw1 wrote:Check out Leading Edge Exhaust if you ever have to replace the entire exhaust system.
http://www.wemakeyoufly.com/piper-aircraft-exhaust-systems/piper-pa-2022-150-160-180hp/

The LE system positions the muffler just like the stock exh system-- aft of the engine next to the firewall. IMHO the Sutton is a better set-up-- the muffler mounts below the engine. Mush less exh tubing and a much cleaner firewall area, making it easier to access mags or to mount a remote oil filter or firewall battery.

Not sure if the Sutton would work with a nosedragger though-- looks like there'd be a space conflict with the nosegear extension on the engine mount.

I don't think the sutton will fit with the nose wheel. For any tail wheel piper, the sutton is the way to go. I put the atlee hot rod muffler on to replace my stock. Both the atlee hot rod and heavy duty eliminate the AD