Saito 100 muffler manifold problem.  
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Saito 100 muffler manifold problem. - 4/18/2008 1:11:27 AM   
Gauch


 

Posts: 15
Joined: 12/29/2005
From: Charlotte, NC, USA
Status: offline 		I've had to replace my muffler manifold (pipe between engine and muffler) twice in the past 4 weeks. Each time the break was at the section of the threads next to the header end of the pipe. Both prop and spinner are balanced. Very little engine vibration observed. Horizon Hobbys solution is to replace the pipe free of charge but they have no idea of what's causing it or how to prevent it from happening again. Any thoughts.....
       Post #: 1

RE: Saito 100 muffler manifold problem. - 4/18/2008 1:42:48 AM   
w8ye



Posts: 16975
Joined: 12/11/2001
From: Taylortown, OH, USA
Status: offline 		There are three different designs of these.

Straight all threaded

15 degree bend

30 degree bend

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Original AMA #31261

(in reply to Gauch)
       Post #: 2

RE: Saito 100 muffler manifold problem. - 4/18/2008 2:16:41 AM   
pumbadog



Posts: 201
Joined: 10/23/2006
From: Newton, KS, USA
Status: offline 		I have a Saito 100 and the original pipe broke at the thread as you described. My LHS had one that was bent at an angle instead of curved, it fit so I bought it. So far this ones ok. The wall thickness on these is really thin and then when it's threaded, it's worse. If yours is like mine, it would get loose and have to be retightened regularly. I think when these are torqued down it stretches the thread and creats a crack then just breakes off. Luckily mine was held to the aircraft by the pressure line so I didn't lose the muffler.

(in reply to w8ye)
       Post #: 3

RE: Saito 100 muffler manifold problem. - 4/18/2008 2:29:17 AM   
Broken Wings



Posts: 382
Joined: 1/15/2003
From: Port Saint John, FL, USA
Status: offline 		My guess would be a manufacturing defect. If you had a thread micrometer you could measure the minor diameter of the thread and see just how much material is left holding the muffler/header pipe on the engine.

It's probably getting thin right at that joint. The header gets hot, cold, hot, cold and work hardens until it gets brittle and breaks or cracks. Maybe you could fabricate a small aluminum stay or bracket to help keep the muffler from moving. Kind of like a motorcycle "P" clamp.

Just a thought.

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Regards,
John

(in reply to w8ye)
       Post #: 4

RE: Saito 100 muffler manifold problem. - 4/18/2008 2:51:51 PM   
blw



Posts: 4420
Joined: 3/15/2004
From: Auburn, AL, USA
Status: offline 		The straight, all threaded manifold is meant to be a breakaway type.

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RE: Saito 100 muffler manifold problem. - 4/21/2008 6:23:25 PM   
chuck993


 

Posts: 234
Joined: 1/17/2007
From: Virginia Beach, VA, USA
Status: offline 		I have a Saito 100 sitting in a box, third time the muffler broke and it broke the cylinder and Horizon will not fix it, they claim they never heard of this before and I posted this info in another thread and some Saito ***** reamed me, they believe it can't be true and that it must be my fault, the Saito ***** always claim they have never heard of a problem with Saito or mufflers even though I've run into several people with the same problem as mine...$300 piece of junk...O.S. is a much better engine and much better quality, go to O.S.

< Message edited by blw -- 4/22/2008 2:19:03 PM >

(in reply to blw)
       Post #: 6

RE: Saito 100 muffler manifold problem. - 4/21/2008 7:11:42 PM   
Hobbsy



Posts: 10354
Joined: 12/2/2001
From: Colonial Beach, VA, USA
Status: offline 		How about a picture there Chuck, I have 17 Saitos, I've never broken a muffler nor ever had one come loose. I don't buy it.

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Giant Saito, 73.2 Cu. In., 70.5HP @ 5,800 rpm, 79 ft. lbs torque @ 3,500 rpm, 57 mpg, 3.50 bore, 3.81 stroke. 563 lbs.

(in reply to chuck993)
       Post #: 7

RE: Saito 100 muffler manifold problem. - 4/21/2008 8:30:27 PM   
chuck993


 

Posts: 234
Joined: 1/17/2007
From: Virginia Beach, VA, USA
Status: offline 		yeah right...none of the Saito nuts ever believe that something could be wrong with Saito...search the forum, open your eyes, that's how I found this one...LOL

drink the Saito Cool Aide!

(in reply to Hobbsy)
       Post #: 8

RE: Saito 100 muffler manifold problem. - 4/21/2008 8:54:59 PM   
wcmorrison



Posts: 766
Joined: 10/2/2002
From: Weatherford, TX, USA
Status: offline
quote:

ORIGINAL: blw

The straight, all threaded manifold is meant to be a breakaway type.


Thats not a bad thing, better to break a pipe than a head. I had have Clarence Lee fix my head, albeit it was a OS four stroke, but same issue.

Cheers,

Chip

(in reply to blw)
       Post #: 9

RE: Saito 100 muffler manifold problem. - 4/22/2008 2:38:18 AM   
scott17


 

Posts: 64
Joined: 12/30/2006
From: Bedford, TX, USA
Status: offline 		I posted pics of 2 broken in a row on my saito 56. I ended up going with a flex pipe. It happens....

(in reply to wcmorrison)
       Post #: 10

RE: Saito 100 muffler manifold problem. - 4/22/2008 1:41:49 PM   
Hobbsy



Posts: 10354
Joined: 12/2/2001
From: Colonial Beach, VA, USA
Status: offline 		Chuck, I'm not only a Saito nut but also an Enya, Fox, Webra, SuperTigre, Irvine, LASER and OS nut.

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Giant Saito, 73.2 Cu. In., 70.5HP @ 5,800 rpm, 79 ft. lbs torque @ 3,500 rpm, 57 mpg, 3.50 bore, 3.81 stroke. 563 lbs.

(in reply to chuck993)
       Post #: 11

RE: Saito 100 muffler manifold problem. - 5/10/2008 11:48:22 PM   
Gauch


 

Posts: 15
Joined: 12/29/2005
From: Charlotte, NC, USA
Status: offline 		Meanwhile, back at the ranch.....#3 broke today.......

(in reply to Hobbsy)
       Post #: 12

RE: Saito 100 muffler manifold problem. - 7/3/2008 9:05:27 PM   
bingo field



Posts: 866
Joined: 5/6/2004
From: Mt. Morris, NY, USA
Status: offline 		I was just looking to see if someone had found a method to secure the pipe. The original on my 91 split off after about 50 flights, Horizon sent me a new one, no questions asked. But this one keeps loosening up on me. I love the way it runs, but hate having to keep tightening the manifold.

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(in reply to Gauch)
       Post #: 13

RE: Saito 100 muffler manifold problem. - 7/5/2008 3:04:57 AM   
bingo field



Posts: 866
Joined: 5/6/2004
From: Mt. Morris, NY, USA
Status: offline 		#2 just broke. Exactly like the first. The pipe breaks where it exits the head. Does anyone have any suggestions?

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Sign over Ready Room Door: "Complacency Kills" - Thimk

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       Post #: 14

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