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I'm posting this information for no other reason than to share what seemed like a simple muffler replacement becoming a mystery to every source contacted. I'm not going to bore you with all the gyrations but in a nutshell my muffler did not pass the leak test. Ok not what I wanted to hear but another unexpected $1800 for a new muffler...not a huge surprise, it's an airplane, that's what they do! The part number in the Mooney parts manual was 630045-503, I found the same part number when I searched on Spruce and QAA and AWI, etc. Why did I shop so many sources, I'm an aircraft owner, that's what we do! I did learn that pretty much all things GA exhaust system/muffler/risers are all under a single owner. I'm probably the only one that didn't know that. So here is the MYSTERY that seemed to stump all sources mentioned above. I've posted several pictures of my old failed muffler alongside the shiny new one. The risers aligned perfectly with the muffler as well as nice and flat against the cylinder exhaust ports. The ISSUE is where the tailpipe connects to the muffler. My original muffler (overhauled once in 2006) has a slight or subtle bend at the end and slightly (ever so slightly) longer. The new muffler was straight as an arrow and when we dry-fitted the tailipipe, it turned the tailpipe into the firewall rather than down the channel where is belonged. Has anyone else experienced this and if you did, what did you do or how did you correct? Thanks in advance for your input, I look forward to your valuable responses. Rick

Anybody out in Mooneyland replace or repair a muffler lately? Looks like my cones are toast. Rebuild or new?

My exhaust system is original and it is now wearing out. Recently, I've had several repairs done, but my IA tells me, "it's time". The metal is getting pretty thin. I'd actually like to buy a complete, new system with everything except the carb-heat shroud, but am open to a piecemeal solution. Ideas? I do not want to go the Power-flo route due to noise considerations. Who do you recommend for either a total overhaul, or a new system in terms of price and delivery time? Thanks!