EXHAUST OVERHAUL FOR 260C (TURBO)

[Eric Jones]

Looking for some help and/or ideas on what might be available out there from an owner who has familiarity with a shop or ???? I am in the process of putting in a Lycoming Direct engine in the 260 Turbo. Trying to find ideas, maybe someone who has done this recently that can direct me to a shop other than DAWLEY, AWI, and ACORN WELDING??? Maybe you have someone who has done this, may have parts even in stock??? The initial price I received from DAWLEY was jaw-dropping! Maybe that is the 'best', but I am hoping someone can maybe provide some information that would lead me in a different more positive direction?????

[Charles Schefer]

Eric,

I recommend you contact Aerospace Welding http://awi-ami.com/

They came highly recommended to me. A few months back I had a cracked exhaust on the join of my #1 and #2 cylinders on the left engine. Everyone I called for help from Webco to local shops all steered me to Aerospace Welding. They took my old exhaust pipe, reused the flanges and replaced everything else. Supplied me with new nuts, gaskets, etc.. and it fit perfectly and came with 8310-3 paperwork. The bill with shipping was $463.84. I thought about having them re-do all my exhausts but that would be 4X the price and they actually talked me out of it. I'm always impressed when a shop talks me out of spending money that they could otherwise get from me. They told me the failure I had was not indicative of all the other pipes going per-se and that most of the existing pipe was in good shape.

Good Luck,

- Charles

[N3322G]

AWI O/H all the Twin's exhaust stacks - however, one of four did not fit well and one had to be un-installed, shipped and re-installed at my expense after it was found at next annual. AWI did the work free of charge but other out of pocket expenses and downtime were on me. They also blamed the problem on the Gulf Coast stack extensions. The stack extensions had been installed for over a decade so likely not the cause of the problem.

Glad to hear they did god work on Charles Twin and happy with 75% of the work done for my Twin.

[Charles Schefer]

Pat - glad you mentioned the stacks. I have Gulf Coast Stacks as well. In my case I did not have AWI pipes to begin with and I wasn't calling for warranty but when I asked them if they would pre-drill the little hole for the Stack the guy there told me "oh... I should tell you that any exhaust extension voids our warranty but I won't put it on the paperwork that you have them". He said that they've had problems with extensions adding weight and causing cracks. The example he gave is those loooooonnnng extensions you see on Cessna 172s that go all the way to the tail. I said that I could understand that but I can't possibly see how the little Gulf Coast stack extensions could make that big a difference. They are very short AND they are right after the exhaust hangar at the factory tip. So any added weight of the stack (minimal) will really be borne by the hangar not the pipe. He agreed with me and said he was telling me just FYI.

When we got the pipe we drilled the hole for the GC Stack clamp pin hole and put the stack back on. My stacks have been on for about 7 years according to the logs and the problem I had was not related to them.

Some other important things with exhaust pipes - never mark them with a lead pencil, it sets up a galvanic reaction with the stainless steel and can crack the pipe. Mark with a sharpie if you need to. That may be old news for most but it's something I learned dealing with my pipe a few months back.

- Charles

[N3322G]

Our extensions were on for over a decade with zero issues. They knew they were on the plane because we sent them along and had them cleaned up.

Post problem, I sent a letter documenting the stacks had been on the plane for over a decade, thanking them for honoring the warranty and suggesting they check their jig.

Clifton had told me of one set of Twin Comanche exhausts that had to be sent back several times because they didn't fit in the cowling - with no extensions on them. so when mine went it initially, Clifton made special notes to have them checked in the jig before returning. Like I said 3 of 4 were fine.

[BSAND47]

Earlier this year I overhauled the engine and exhaust from my 400. Sent 4 stacks, 2 crossover pipes, 2 mufflers and shrouds to Dawley.
They did excellent work, on time, and on budget. Wasn't the cheapest, but also wasn't the most expensive!

As a side note, I mis-drilled a hole in the inlet pipe to one of the mufflers. Sent it back to Dawley, they welded and refinished it - no charge!

Bill

[Eric Jones]

Thank you for the replies..........Dawley is in my 'backyard' literally (KBUU), but I thought "$8,000 'minimum', maybe 9,000"....... was crazy............we will continue to search and review.........


Eric