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Zenith CruZer & Sonex Logs
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Date: 2-20-2011
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Number of Hours: 1.50
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Manual Reference: aerovee
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Brief Description: Exhaust Pipe Trimming
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I can't finish the firewall forward connections to the RDAC until the exhaust was completed (because I'd have to be removing and replacing the EGT sensors in the exhaust headers), so I finished up trimming the exhaust parts today. Now I can permanently install the headers with flange gaskets, mount the EGT probes, and finish the wiring.
Two trimming operations are required per side. The exhaust system has two parts on each side - the basic two-into-on header, and then an extension pipe. The headers had to have about 0.5" removed from each end, because the extensions were hitting the lower motor mount crosspiece. So I removed each header, marked 0.5" from the end, and used a cutoff disk in my Roto-Zip to trim it off. The left side required a second cut - the header sat just a bit further aft, so I had to remove it again, trim, and reinstall.
Next came trimming the ends of the extension pipes. As supplied, there's plenty of length, as shown in the first pic below, but they should not hang too far into the slipstream due to drag concerns.
I used a straightedge and marked a line corresponding to the lower fuselage skin. I then marked 1" below that, and using the same cutoff disk, trimmed each end. I could probably trim them a bit further, but I didn't want to start out too short. Once the cowl is fitted and the exhaust cutouts made, I'll do additional trimming if desired.
Next up is to install the headers with flange gaskets, install the EGT probes, and finish wiring. I still also have to locate a fastener point on the firewall to support springs holding up the ends of the exhaust extensions.
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Trimmed Pipe (Top)
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Just positioned; not secured
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