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Muffler Problem - Advice Needed

 
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rdwest(at)shaw.ca
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PostPosted: Thu Sep 18, 2008 12:29 pm    Post subject: Muffler Problem - Advice Needed Reply with quote
Hi Listers,

I need some help.

I built a Zenair CH-601-HD kit back in 1993 /95.

It has Rotax 912 Engine with Zenair firewall-forward kit that included engine mount, mufflers, etc.

The original left side muffler has recently failed in flight, breaking at the front elbow.
It was made with regular carbon steel (not stainless), and appears to have failed due to corrosion and vibration over the years.
I have attached a few photos for reference.

Zenith has been very slow / reluctant to respond to my RFQ so far, other than to tell me they don't have the old muffler system in stock.
Even that took 1 month, 5 emails and 30 minutes trying to get thru on the phone. Very frustrating, especially since I am also still trying to sell my plane.
 
It is the old dual-muffler design that I need in order for it to fit in the original cowling (I assume).
I think the newer models use single muffler (SS).

Any other possible sources for these custom parts?
Or other general advice?

Thanks in advance.


Darryl West
rdwest(at)shaw.ca (rdwest(at)shaw.ca)
Calgary, AB

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psm(at)att.net
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PostPosted: Thu Sep 18, 2008 1:22 pm    Post subject: Muffler Problem - Advice Needed Reply with quote
Hi Darryl,

Have you tried talking to your local muffler shop? In the typical shop they can whip together just about anything you want.

Paul
XL getting close


At 01:29 PM 9/18/2008, you wrote:
[quote]Hi Listers,

I need some help.

I built a Zenair CH-601-HD kit back in 1993 /95.

It has Rotax 912 Engine with Zenair firewall-forward kit that included engine mount, mufflers, etc.

The original left side muffler has recently failed in flight, breaking at the front elbow.
It was made with regular carbon steel (not stainless), and appears to have failed due to corrosion and vibration over the years.
I have attached a few photos for reference.

Zenith has been very slow / reluctant to respond to my RFQ so far, other than to tell me they don't have the old muffler system in stock.
Even that took 1 month, 5 emails and 30 minutes trying to get thru on the phone. Very frustrating, especially since I am also still trying to sell my plane.

It is the old dual-muffler design that I need in order for it to fit in the original cowling (I assume).
I think the newer models use single muffler (SS).

Any other possible sources for these custom parts?
Or other general advice?

Thanks in advance.

Darryl West
rdwest(at)shaw.ca (rdwest(at)shaw.ca)
Calgary, AB


[b]

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macleod(at)eagle.ca
Guest
PostPosted: Thu Sep 18, 2008 2:54 pm    Post subject: Muffler Problem - Advice Needed Reply with quote
Darryl:

If you cannot get the job done at your local muffler shop as others have
suggested, I believe, looking at the photo of your cowling that the new
single muffler would fit. I got mine from Zenair Europe.

I think your best bet is to phone Nick H. (in France) and discuss your
problem with him. You can get his phone # from Zenair in Midland.

Mike
601XL - painted, final assembly about to start

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jlatimer1(at)cox.net
Guest
PostPosted: Thu Sep 18, 2008 5:06 pm    Post subject: Muffler Problem - Advice Needed Reply with quote
Darryl,

I'm finishing an HDS (1999 vintage kit) with a 912S. I have the same cowl that you do and the old style bed motor mount. I have the single muffler system and from looking at your photos, I think it will fit your HD as others have pointed out.

Jerry
---- "Darryl West (Home)" <rdwest(at)shaw.ca> wrote:
Quote:
Hi Listers,

I need some help.

I built a Zenair CH-601-HD kit back in 1993 /95.




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ggower_99(at)yahoo.com
Guest
PostPosted: Fri Sep 19, 2008 8:43 am    Post subject: Muffler Problem - Advice Needed Reply with quote
Hello Darryl,

You can get in touch with Mark, in Can Zac, if the new muffler (stainless steele) fits in the older HD fireward forwasd area, he might order one for you. Depends how the instalation of the radiators and the muffler is arranged in your HD.

In case the SS muffler will not fit, you can visit your local car muffler shop. If is a good shop they can copy your muffler and make a new one exactly as yours, good for about 10 years more.

Saludos
Gary Gower.
Flying from Chapala, Mexico.

--- On Thu, 9/18/08, Darryl West (Home) <rdwest(at)shaw.ca> wrote:

Quote:
From: Darryl West (Home) <rdwest(at)shaw.ca>
Subject: Muffler Problem - Advice Needed
To: zenith-list(at)matronics.com
Date: Thursday, September 18, 2008, 4:29 PM

Hi Listers,

I need some help.

I built a Zenair CH-601-HD kit back in 1993 /95.

It has Rotax 912 Engine with Zenair firewall-forward kit that included engine mount, mufflers, etc.

The original left side muffler has recently failed in flight, breaking at the front elbow.
It was made with regular carbon steel (not stainless), and appears to have failed due to corrosion and vibration over the years.
I have attached a few photos for reference.

Zenith has been very slow / reluctant to respond to my RFQ so far, other than to tell me they don't have the old muffler system in stock.
Even that took 1 month, 5 emails and 30 minutes trying to get thru on the phone. Very frustrating, especially since I am also still trying to sell my plane.

It is the old dual-muffler design that I need in order for it to fit in the original cowling (I assume).
I think the newer models use single muffler (SS).

Any other possible sources for these custom parts?
Or other general advice?

Thanks in advance.


Darryl West
rdwest(at)shaw.ca (rdwest(at)shaw.ca)
Calgary, AB

[quote][b]

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klaus(at)utdallas.edu
Guest
PostPosted: Sat Sep 20, 2008 4:16 am    Post subject: Muffler Problem - Advice Needed Reply with quote
Hi Darryl,

When we built our 601 HDS, it also had the muffler system that you
have described. After a short time, the elbows of the system failed
and I got stainless steel versions from Zenith. Then I finally decided
to replace the entire system with a single muffler, with exhaust pipes
and muffler made of stainless steel. But I kept the old system:
stainless steel elbows and the two mufflers of carbon steel. The latter
had to be made a bit smaller at one end due to the cowl. But it all
is there and still works. If you like, I can mail you everything if
you pay for the shipping charges.

Please let me know very quickly. I am leaving town the coming week
and will return in early November. Of course, if there is no time
pressure, everything could be done in November.

Best wishes,

Klaus

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