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Exhaust fitment question - Replacing Header pipe

in 912 / 914 Technical Questions 6 years ago
I need to replace a cracked exhaust pipe. I'm curious what the best practice is when replacing pipe(s). Is it best to remove all the exhaust springs, loosen the header locknuts on all the pipes, then align the muffler with all the pipe ends, then torque all the locknuts on the exhaust pipes?

I tried today to replace the one pipe while leaving the rest of the exhaust muffler and springs in place and it seems very tricky to both align the pipe into the muffler while properly aligning the header pipe.

any advice?

thanks.

John

  • Re: Exhaust fitment question - Replacing Header pipe

    by » 6 years ago

    The Exhaust system is the subject of more corrosion and abuse than any other part f the power plant.

    As long as your in there taking things apart, you might as well do it right!
    Take all the joints apart and re-apply the coating to of High-Temperature Copper based Anti-Seize Compound to every joint and fitting that you will ever want to take apart in the future.

    Replace any muffler springs that look suspect, and don't forget the Anti-vibration Silicone and the safety wiring on the springs.

    This is a part of the maintenance of the exhaust system.
    See the 912 Series Line Maintenance Manual Section 05-20-00, Page 5.

    Bill Hertzel
    Rotax 912is
    North Ridgeville, OH, USA
    Clicking the "Thank You" is Always Appreciated by Everyone.

    Thank you said by: John Walsh
      
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  • Re: Exhaust fitment question - Replacing Header pipe

    by » 6 years ago

    I usually loosen the front two exhaust pipes and then put all the springs on and get it aligned and then go back and tighten the exhaust nuts. I usually tap the muffler with a rubber mallet before tightening to just make sure the knuckles are all seated fully.

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell

    Thank you said by: John Walsh, Nick
      
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  • Re: Exhaust fitment question - Replacing Header pipe

    by » 6 years ago

    Thanks for the advice guys. What tools are you using to remove and replace the springs? I've been using Craftsman Professional 4 piece Hook and Pick set to grab the spring ends. It's really nasty work with these tools. There are 3-4 springs that are really difficult to get at on my aircraft.
      
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  • Re: Exhaust fitment question - Replacing Header pipe

    by » 6 years ago

    Because there are so many different muffler applications and orientation I use a pair of 12" long needle nose pliers. I took my Dremel tool with a reinforced cut off wheel and cut about 6-7 notches across each side of the pliers jaws. This allows the pliers to grab and not slip. Then I can use my body weight and full upper body weight to install or remove springs. Some springs to are heavy duty and some a lighter duty spring. The lighter duty ones are easy. Using your body weight is far easier than just your wrist.

    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell

      
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  • Re: Exhaust fitment question - Replacing Header pipe

    by » 6 years ago

    Thanks again. I'll get the dremel out. You cut the notches to the same dimension as the spring wire diameter? I was looking at the spring tool that LEAF and others sell, but it didn't look vastly different from the craftsman stuff I had.
      
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