New Project

[Av8r3400 1178]

I was going to go for a flight tonight.  During the preflight I pulled the prop through as normal and heard a metallic rattle.  I though to myself, "Damn.  Broken exhaust spring."

 

So I pulled off the cowling.  All of the springs were fine.  There was still a rattle in the exhaust, though.  On closer examination I found this:

 

 

The end of the muffler is obviously cracked.  Scratch one Tuesday night fly night, fly-in.

 

Off comes the muffler to get welded.  After pulling off the muffler I quickly realized that there was more wrong than just a crack on the end of the muffler.  There were loose parts rattling around inside it!!

 

 

I took it over to Dave's place to cut it open and see what's to be seen.  Here's what I found:

 

 

The blast tube inside the muffler loosened on one end and then broke.  This left the stinger unsupported and lead to the crack on the end cap.

 

A call to Kitfox taught me that a replacement muffler is available ($500) but I'd have to send the header pipes along with the old muffler to construct a new one.  They won't sell me just the blast tube.  Therefore I am left to find or make my own replacement.

 

Here's what I found.  Link.

 

Maybe someone makes a 1-3/4" diameter blast tube , but I can too.  For a lot less money.  The material will be here on Friday.

 

 

WIth a little luck I will have it back together for the trip over to OSH on 7-18.  If not, I guess the plane will have to stay home. 

 

 

 

 

 

 

[EDMO 1078]

Larry,

     12" Chrome plated motorcycle glasspacks are cheap on ebay!  Oh, is that a Rotax?

EdMO

Edited 8 Jul 2015 by Ed In Missouri

[akflyer 1427]

Will the muffler off the mangy fox fit this 912?

 

[Av8r3400 1178]

Mangy muffler has been modified for the mangy.

[C5Engineer 1170]

Why does this crap always happen when your trying to get someplace?

[TJay 1041]

Better than getting there and not getting back home.

[Av8r3400 1178]

Yes, TJay.  In it's condition it may have failed and departed the airplane in flight causing who knows what kind of damage.

[jjbaker 73]

Why does this crap always happen when your trying to get someplace?

 

No kidding. Lightly wiggle that exhaust during pre-flight. Just too many things can burn or get damaged + carbon-monoxide poisoning is no fun.

We had a cracked turbo melt his surroundings including part of the wing spar on a twin. No fun, either.