Custom Headers/need help
 

Hey guys, I'm working on a new TOC 1 Extra 330-42% and have serious exhaust problem.
The stock mufflers for the DA 150 will not fit without carving up the motor box. Also, I'm affraid the stock mufflers will not provide required db level for my field.
The plane is not set up for canisters but I can fit them in.
The problem is that the centerline of the canister is 5.562" below the exhaust manifold and there are no standard headers that will accomadate that much of a drop. Also besides the drop, the only possible canister location requires an offset built into each header.
I have puchased bits and pieces of parts from DA to make up a header however, the tubing (28mm) requires bending fitting and silver soldiered joints.
This is truly specialized work if proffesional looking results are to be expected. Also I have contructed a proffesinally designed and built fixture to insure alignment and fitting.
I have not been able to find an exhaust system manufacturer who will make a custom header and this is not the kind of work most machine shops are capable of doing. Especially with metric size tubing.
Any ideas greatfully accepted.

RE: Custom Headers/need help
 

This place makes custom glow pipes maybe they can do custom gas mufflers aswell

http://www.keleo-creations.com/

RE: Custom Headers/need help
 

Thanks Chris, I have emailed them with particulars and am waiting for response

RE: Custom Headers/need help
 

I made a custom header and exhaust pipe for my AW Edge, because no standard header would fit. I bought some peices from Aircraft International and built a jig fixture to hold the parts in place. I took it to my local welding shop and about $50 later I have a great looking header. Sure I could probably have learned how to TIG weld, spent hundreds of dollars on weird fluxes, torches, and rods, but I'm getting lazy!
This is not a specialty shop, just our local welding shop, so I would think you could find one that could do the work. As for Keleo Creations, Kelvin is great and I'm sure could make you anything you'd like. He's currently working on two (soon to be three) scale exhausts for my warbirds.
Sam