Some of you may have received an email recently regarding a defect notice issued by the HGFA about a possible exhaust component problem. The email described a number of incidence of the question mark shaped exhausts cracking on an XT912. I have had 5 cracked exhaust pipes including one catastrophic inflight fracture where the pipe cracked in two resulting in an emergency landing. After extensive discussions with right people at airborne, it has been discovered that the process of making changes to the exhaust needs to be clarified. Many airborne operators I have spoken to have mistakingly followed incorrect procedure for making adjustments to the exhaust. The process described involves attaching the exhaust components to the engine and attaching the springs before tightening any of the nuts that hold the exhaust components to the engine. This is an incorrect process that has resulted in 5 exhaust pipe failures on two seperate trikes in the last 12 months. Two failed exhaust compnents were virtually brand new. As a result of the failures of these new compnents I was led to believe that there might exist a quality control problem with the latest batch of manufactured parts.
I have anecdotal evidence that others have experienced problems with exhaust cracking and or failure. I can list at least one individual that has had two failures. One involving cracking and one catastrophic failure resulting in an emergency landing. In all cases that I have experienced problems, they all occured after the exhaust was worked on. On one trike that was purchased recently, the previous owner was asked to repair some wear to exhaust lugs. The previous owner removed the affected exhaust components and then re-attached the exhaust using the above mentioned method. 15 hours later I had two cracked question mark pipes. My first cracked exhaust about 12 months ago occured shortly after an EGT probe was replaced where the exhaust part was removed to make the repair easier. Recent failures of new parts all occured after exhaust components were removed.
It appears quite clear that any tampering with the exhaust that involves the adjustment of the nuts holding the exhaust to the engine induces stress in exhaust components. In order to ensure exhaust longevity all exhaust stress needs to be elliminated at time of installation. This kind of exhaust stress is the major cause of premature failure in the question mark pipes.
The correct procedure for elliminating exhaust stress is to align the exhaust the following way whenever any exhaust parts are separated from the rest of the exhaust:
1. loosely attach the exhaust components to the engine.
2. Slowly tighten the nuts to the question mark shaped pipes constantly checking that the mufler can be easily moved with the pipes in place. The mufler should be rotated 180 degrees to ensure it is properly aligned in both directions. When the nuts are properly tightened the mufler should be able to be removed from the pipes without any stress on either of the pipes.
3. Do the same with the two horizontal pipes under the engine with the muffler in place. These pipes are not as critical as the two shorter pipes since they are longer and have a greater degree of flexibility.
4. Finally, once all the pipes are aligned and tightened in place, attach the springs.
Note: Make sure you use antiseize grease on all the joints.
This method needs to be followed whenever any of the nuts holding exhaust components are either loosened or tightened as their adjustment will cause stress (especially problematic for the short pipes). For instance the short pipes will move horizontally either left or right when either nut is adjusted resulting in the build up of stress on each of the short pipes.
It is no surprise that many are not aware of the correct procedure for working on the exhaust as very few have ever had to touched it. If you do however, beware of the consequences of doing it the wrong way.
I believe it is in Airbornes best interest to include written instructions whenever supplying new exhaust components to their customers. They are yet to do this and in my opinion should bare some of the responsibilty for any problems caused when the new parts fail prematurely. I have checked the XT912 maintainance manual and no mention of any procedure is included. It does however state that you should call them to arrange for any new exhaust parts you might need to order.
Finally, it is important to realise that the process of changing exhaust springs will not require a full exhaust alignment as none of the nuts are adjusted for this process.
Bluey.