'65 M20C Exhaust has Major Cracks

[Fusco]

I purchased a 1965 M20C as my first ever airplane and although the performance has been a nice step up from 172s, I definitely have not been lucky with the maintenance. It is in its first annual since I've owned it right now out of N87 and the mechanics have been searching for a new exhaust system because as it stands right now, according to them the exhaust has major cracks that are beyond weldable at this point. I know it's a reputable shop so I haven't pushed back too much on it and they have been struggling to find anything for several months now. I'd like to avoid having a new exhaust built because the cost of that plus the annual would be quite brutal. I thought it wouldn't hurt to reach out on here to see if anyone has any connections that could maybe point me in the right direction. 

Any advice would be much appreciated because as a first-time owner, this whole situation has been tough!

[Ragsf15e]

28 minutes ago, Fusco said:

I purchased a 1965 M20C as my first ever airplane and although the performance has been a nice step up from 172s, I definitely have not been lucky with the maintenance. It is in its first annual since I've owned it right now out of N87 and the mechanics have been searching for a new exhaust system because as it stands right now, according to them the exhaust has major cracks that are beyond weldable at this point. I know it's a reputable shop so I haven't pushed back too much on it and they have been struggling to find anything for several months now. I'd like to avoid having a new exhaust built because the cost of that plus the annual would be quite brutal. I thought it wouldn't hurt to reach out on here to see if anyone has any connections that could maybe point me in the right direction. 

Any advice would be much appreciated because as a first-time owner, this whole situation has been tough!

You can generally send your old exhaust to awi or Acorn or any other aircraft welding facility no matter its condition.  It will come back looking like new.  Have you or the mechanic contacted them?

[Fusco]

2 hours ago, Ragsf15e said:

You can generally send your old exhaust to awi or Acorn or any other aircraft welding facility no matter its condition.  It will come back looking like new.  Have you or the mechanic contacted them?

I will give them a call in the morning and see what they say. Thank you for the response! 

[Kelpro999]

3 hours ago, Fusco said:

Any advice would be much appreciated because as a first-time owner, this whole situation has been tough!

One on EBay for 400. Worth investigation 

[hammdo]

Pretty much what I’ve been doing - as I discover items, get them done… 

David (sabremech) did a lot before I bought her, I’m continuing that approach…

-Don

[Fusco]

4 minutes ago, bluehighwayflyer said:

@Ragsf15e is right.  Get it rebuilt correctly and you will probably never have to deal with it again.  Every year if you do that to a few systems over time your entire airplane will be restored.  That is all part of vintage airplane ownership.

Here is another option …

https://knisleyexhaust.com

Jim

I'll certainly be looking into it thank you! Do you know what something like this would typically cost? 

[Fusco]

4 minutes ago, bluehighwayflyer said:

I don’t, unfortunately.  When we were faced with this dilemma my dad chose to install a PowerFlow exhaust.  It has served us well as is an upgrade, but if I was in your position I think I would just rebuild what you have.  

Jim

https://www.powerflowsystems.com

 

Thanks for the advice! Does rebuild mean having someone weld the cracks? Or does it mean having a new exhaust custom built for my airplane? Sorry, I'm still pretty new to all this! 

[Fusco]

11 minutes ago, Fusco said:

Thanks for the advice! Does rebuild mean having someone weld the cracks? Or does it mean having a new exhaust custom built for my airplane? Sorry, I'm still pretty new to all this! 

Actually I think I understand. Do you send out your exhaust to AWI or another company and they fix it up and send it back? 

[hammdo]

Mine before and after: Dawley did it before he retired. AWI bought him out… (David @Sabremech sent it out and did the install for me).

 

[47U]

6 hours ago, Fusco said:

Any advice would be much appreciated because as a first-time owner, this whole situation has been tough

It gets easier the longer you are an owner, or, perhaps, you just become numb to the reality of the outgoing amu’s.

If you have an alternator (replacing the original generator), the powerflow exhaust is an upgrade many vintage Mooney owners have been happy with.  If you still have a generator, it protrudes too far back into the lower cowl and interferes with the powerflow installation.

 

[cliffy]

Unfortunately waiting :months" for an exhaust system fix is just not right. 

Any of the above mentioned shops can reweld and repair your system in a few weeks.

Get your shop to call any of them and get it sent off

SEND ALL THE PARTS NOT JUST WHAT THEY THINK IS BAD SEND THE COMPLETE SYSTEM

It comes back as good as new

Going this way is probably cheaper than the PowerFlo system.  

Can you elaborate on what your problems have been with annual and maintenance?  You can PM me if you want. 

[RLCarter]

I just replaced the complete exhaust system on an 0-300 (6 cyl) 172, just south of 3 grand, only needed both mufflers and 1 riser, but elected to just replace it all, besides it looks good bolted to the 6 new cylinders….

[Skates97]

@Fusco, I put a Power Flow in my 65 D/C a few months back. The old system is sitting in a box in my hangar. It is serviceable without any cracks, it does have holes in it for EGT sensors. If you are interested I can send pics and we can figure out what it's worth. Send me a PM if you want.

If you go the rebuild route, my understanding is that to call it a rebuild they just have to use something from the old system which is usually a flange, everything else is new.