Hanlon-Wilson Exhaust

[Holcombe]

My mufflers do not have any baffles in them. Is this correct?
Or have baffles disintegrated and and been scattered across the countryside?

[MikeB]

Both my HW and Cessna mufflers have baffles so I expect they're 'missing in action'. If you can get your hands on a bore scope or the 'cheepie' that Harbor Freight sells you should be able to shove it up the tail pipe outlet and see if there are any remnants.
Mike

[Holcombe]

Thanks, I will begin the process of finding a fix or replacements by asking, Any free advice/guidance out there?

[EDGEFLY]

Holcombe,
Sorry I can't offer a good repair philosophy but have a question for my own interest. Do you know how long the H-W has been installed ? I have the standard exhaust on my Chief and am long-suffering in the cold weather. Have considered many fixes and , of course, H-W is among them. Has your A/C ever lived in a salt environment or been on floats so as to have been around water a lot ?

Dale

[MikeB]

Holcomb (although I realize you're on the west coast) I've had good luck with Dawley Aviation in Burlington, Wisconsin 1-800-338-5420 on rebuilding exhaust systems. I'm going to send the HW exhaust from my 11CC Chief project when I get to that point. Even if you can supply one part I understand they can build you a whole system. I guess some, who may chime, in have used the exhaust built by "SonnY Porch" (think that's the name) but unsure if they're certified. There also maybe some good rebuilder on the west coast, I suppose.
Mike

[rkittine]

Sonny Porch rebuilt mine and did a wonderful job. According to my mechanic, repair of existing and remanufacturing of parts no longer available was legal, but I could not prove it. He did a great job all in S/S and look and work great.

Bob

[Holcombe]

Thanks all for the leads. Other than the missing baffles, mine has stood up well for years. I have no idea how many but was old about six hundred hours ago when I bought the plane.

[DRP]

My 1958 Champion 7EC is in for annual now and my HW exhaust system has problems. The flanges are worn, one is cracked and the baffles are disintegrating on both sides. Am I better off pursuing repair or buying a new system? I am located in upstate NY near the Canadian border. Any advice on pricing or referrals to repair shops would be appreciated...

[rkittine]

I know that a lot of people have purchased exhaust systems off of 0-200s in Cessna 150s that totaled or junked. The last one I saw sell in excellent condition went for $700.00.

Bob

[Holcombe]

I can't imagine a mechanic knowing the difference between an O-200 Cessna exhaust and an original H-W. Maybe if I saw them side by side, then hid the old worn out one.

[MikeB]

I have approved paperwork for the Cessna 150 on the 7 series. Both my Champ and the L16 had the 150 system. Basically the 150 has straight stacks from the engine to the muffler whereas the HW has 'bent' stacks. The Cessna tail pipes require that the lower cowl exit holes be rearranged. The HW will exit through the original holes and are listed in the type certificate. Having said that, the Cessna system works just fine for anything from A65-0200.

[Holcombe]

Had a feeling there would be some differences. Seems the more you know, the more complicated things get.
I'm having trouble getting past "any level surface tends to collect a mess"

[DRP]

Thanks for all the comments. After a few phone calls, and on the strength of the recommendation above, I decided to pack up the whole system and send it out to Dawley Aviation. My tailpipes appear to be serviceable, the shrouds will need some repair to be serviceable, but the risers and the mufflers will probably need to be replaced.

The C150 option would be cheaper, but I've never had to put any money into this plane in 8 years of ownership, so I decided to bite the bullet. Also, I don't want two new holes and two patches in my lower cowling to accommodate the C150 system.

I will post on the progress when I have more info. It will be interesting to see if I get any performance difference out of the new system...

[DRP]

Good service. All but the tailpipes need to be replaced. $1474 price tag was disappointing but this plane owes me nothing.

[MikeB]

I guess considering these HW and Cessna exhaust systems have probably been on for plus or minus 50-60 years spending $1500 isn't too bad. Just a shock when the time comes. Usually the flanges are burned out, shrouds cracked and the fire cones burned out. I have a flexible scope that I shove up the tail pipe to check the fire cones during the annual (insert joke here ). I bought it from Harbor Freight for about $65 on sale.

I lucked out on the Chief HW exhaust system as I bought a rebuilt set with shrouds, risers, etc. for $900. Included the paperwork. My old one was pretty much burned out.

Mike