For most owners, the exhaust system is an out-of-sight, out-of-mind portion of the airplane. It’s certainly not a sexy part of any aircraft—even the FAA’s description of the exhaust system in its Airframe and Powerplant Mechanics Powerplant Handbook is a little off-putting: “…a scavenging system that collects and disposes of the high-temperature, noxious gases as they are discharged by the engine.” Nevertheless, all exhaust systems deserve a great deal of respect and your attention and consideration because they live in a horrible environment of intense heat, flame, corrosive gases and vibration. Plus, if any component fails, the risks are nothing short of serious: carbon monoxide poisoning of the aircraft occupants, partial or total engine power loss and fire.
Despite being made of materials designed to withstand the nasty process of ducting the products of combustion overboard, exhaust systems will eventually wear out and need to be repaired, overhauled or replaced. When that time comes, what are your options and what is it going to cost? We’ll go through a brief discussion of the makeup of exhaust systems, how they are inspected, what’s most likely to go wrong and what is available when your exhaust system has done its job and is ready for retirement.