0-235 Exhaust Leak Solutions

[Dave in Eugene]

I have an exhaust leak at the flange of one of my cylinders on my 0-235 L2C

It appears that there are a few options and I am searching for others.

1) Send it off to Aero Space Welders (or "fabricators" my A&P wasn't sure of the name) and have them re-weld the flange on a jig.. Solution around $200 and easy install

2) Go with a new Hal Hunt exhaust system that will cost $700 and re-engineer the baffles and cowl to accept them. (Is there a power/ speed increase over the original exhaust that exit though holes in the cowl?)

I am looking to the collective wisdom of the group on this one as I am not sure what to do.

Thanks,

Dave

[Drew]

4 individual pipes will make more power.  The Hal Hunt pipes "tuck in" which will allow you to get rid of the exhaust "humps" on the lower cowl as well as not needing a special opening in the cowl for its exit.  If you visit my website, you will see Hal Hunt pipes on my Longez (as well as a very much simplified baffling system if you go to downdraft).

You can also check out berkut13.com for a slightly different 4 pipe exhaust and a very nice baffling for updraft cooling that is far superior than plans.  If Dick Rutan and Mike Melville are not using berkut baffling, they are using something that looks VERY similar.