Exhaust System Check

Tips for Checking Your Exhaust System

by AWI

  • Remove all shrouds and shields from the muffler and stacks to permit full inspection

  • Look for signs of leaks
    • Examine surfaces next to the exhaust system for signs of exhaust soot.
    • Examine the exhaust components for red, orange, yellow or gray stains around welds, clamps and flanges.
    • Check connections for proper fit.

  • Metal Fatigue - Inspect all surfaces for bulges, distortions, and cracks.
    • Examine bends in pipes for pitting and thinning of material.
    • Use a awl to probe material in suspected weak spots
    • Use a flashlight to shine into pipes for inspection
    • Use a Borescope to examine internal components
    • Damaged or missing heat studs, fins or other heat sink material can cause uneven heating of the muffler surface and lead to holes in the muffler can.
    • Baffles - Look to see if the muffler has internal baffles or tubes. If they are damaged or missing replace the muffler. Broken baffles may become dislodged and restrict the outlet and cause power loss.
    • Internal damage - carefully inspect internal components for wear, pitting, cracks, broken baffles, corrosion may be occurring on a component that looks good externally.

  • Installation tips:
    • Don't force fit any parts, cracking will occur and shorten component service life.
    • Make sure that all parts are properly aligned, first loosely mount on aircraft then tighten all connectors to OEM specifications, retighten after a hot run.
    • Do not reuse gaskets- AWI has most of the common gaskets in stock.
    • Lubricate all slip joints with a high temp. anti-seize rated to at least 1600 degrees F. Bostic Never Seize and C5-A are two good anti-seize compounds.

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