BTW, I am going with the ES40G in the Extra. There's plenty of room in the tunnel for this. The internals are identical to the 30G I have on hand, but I need the 30G for my pattern plane. Going to learn something either way.
I am staying with the fiberglass tape coupler for now. But I am very interested in what you find out with the turbo hose. I've drilled and tapped the pipe stem and header for a 4-40 button head screw as Ed Skorepa suggested, which will work like a barb and hold the coupler material better. I am using the tape alone with stainless steel wire ties. It needs cooling air over it to keep the silicone adhesive cool enough so it can provide a good seal and not melt.
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Regards,
MattK
Good idea with the button-head screws. If my JB Weld lip around the pipe doesn't work I'll try that - along with the turbo hose - just to see how it works.
Seems as if we are in somewhat new territory here, with soft mounted gassers and tuned pipes in pattern planes. Precious few references when searching RCU and elsewhere.
It'll be interesting to see what Dan (Gungadin) finds with his hard-mounted engine. Probably less stress on the coupler, but perhaps more on the header/exhaust flange(?)... or perhaps not?
I toyed with the idea of a fully-enclosed pipe with the Focus, with the pipe tunnel completely inside the fuse, and it could be done with some more serious carpentry. Much tighter fit for the servos and other components. This fuse isn't nearly as roomy as those of your modern wide-bodies!