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Advice sought - exhaust cracking

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  • Advice sought - exhaust cracking

    Hi guys,

    I need some advice. My left exhaust pipe has cracked in the exact same place 3x now which has got me scratching my head. The first time I reasoned that it was the result of the cylinder issue that occurred 14 months ago. However we did another repair on it a few months ago with reinforcing, and it has now cracked again after only 30 hours. The welding was done by a professional aircraft welder and each time it has cracked beside the weld. It's occurring on the aft plate of the heat muff where the pipe attaches. I can think of a few reasons why it might happen, but I'm very interested in "crowd sourcing" potential causes and fixes from the group. One possibility is that I have added a short section of turned down exhaust tips on recently, although the first cracking occurred before this change. I'm now starting to wonder if it's more to do with the engine movement on the mounts during starting and power applications. It's currently supported from the engine mount so I might see if it can be supported by the engine itself instead. Any ideas appreciated.

    IMG_1466.jpg

    IMG_3026.jpg
    The photo below is of the righthand exhaust, but the mounting and attachment is in the same place.

    IMG_3027.jpg

    The photo below was taken during the build and shows the universal joints.

    IMG_3025.jpg
    Last edited by Nev; Yesterday, 04:04 AM.
    Nev Bailey
    Christchurch, NZ

    BearhawkBlog.com - Safety & Maintenance Notes
    YouTube - Build and flying channel
    Builders Log - We build planes

  • #2
    Hi Nev
    Do you have the hot air shutoff valves set to vent overboard to assist in cooling the exhaust? I have my aft exhaust mounted to the eng so there is no relative motion as the complete exhaust moves with the engine, i have a 100 hours on it now but time will tell.

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    • #3
      On the side with the issue I have removed the outer casing and no longer use it to provide heat. (I discussed it with Clint at the time). So the inner structural section is open to the airflow. But I'm thinking the same thing of mounting it to the engine, that might be the key.
      Nev Bailey
      Christchurch, NZ

      BearhawkBlog.com - Safety & Maintenance Notes
      YouTube - Build and flying channel
      Builders Log - We build planes

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      • #4


        Hi Nev
        This is how I supported my aft end of the exhaust to the engine so everthing moves with the eng no relative movement. 100 hours on so far so good.



        IMG_4005.jpg



        67341234829__5BBC0664-B7C8-435E-B56A-6B1E092757F6.jpg 67348126459__DC561E44-8FCB-4595-8322-8A2894553641.jpg
        IMG_3978.jpg IMG_3977.jpg
        Attached Files
        Last edited by huntaero; Yesterday, 12:21 PM.

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        • Nev
          Nev commented
          Editing a comment
          That looks like a very good way to support it.

      • #5
        More support is definitely worth considering. Also, maybe see what your welder thinks about adding a few beads perpendicular to the one that keeps failing, especially since the crack is so close to the bead? I drew an example in red.
        Attached Files

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        • Nev
          Nev commented
          Editing a comment
          Good ideas, I'll run them past him. Thanks Jared.

      • #6
        It might have to be backup on the inside with ARGON also, as SS needs to have an inert fgas on both sides when welding. Just a thought.

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