PowerFlow Exhaust retro-fit

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perossichi
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PowerFlow Exhaust retro-fit

Post by perossichi »

Folks-

I'm thinking about doing this. I understand this is now standard equipment but I'm wondering if people had experience with the upgrade in terms of performance, fuel economy, etc. I already have the 2 blade Hartzell composite prop.

thanks!

ps I did search the forum for "Powerflow" and didn't find much useful.
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Pilot55
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Re: PowerFlow Exhaust retro-fit

Post by Pilot55 »

I put the power flow on with fine wire plugs and picked up 8 knots. It is well worth it
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Steve
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Re: PowerFlow Exhaust retro-fit

Post by Steve »

perossichi wrote:I did search the forum for "Powerflow" and didn't find much useful.
This came out before this forum was born. I remember a lot of discussions about it and pireps on the old Diamond Aviators forum, but that doesn't exist anymore. I considered it about 15 years ago, but didn't want to mess with the composite work required on the lower cowl. I have the original 3 bladed MT prop, so it would work on my airplane.

Steve
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Re: PowerFlow Exhaust retro-fit

Post by Tom-B »

I previously owned a 2001 DA40 that had a Powerflow and I appreciated the resulting performance increase.
After renting Cirrus 20/22’s and finishing my IFR rating in the Cirrus I realized I missed my Diamond. So I have just purchased a 2002 DA40 and I plan on going forward with this upgrade. It looks like there is currently a promotion that if you wait to take delivery in November you can save $700 dollars and an additional $100 discount if the exhaust is delivered to a PowerFlow dealer.
My AP notified me that PowerFlow is no longer providing the cowl patch kits ($350) so he will need to make the repairs. My 2002 will also need the Arizona Baffle Kit ($750 from Diamond) installed to enhance cooling with the PowerFlow installed.
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Re: PowerFlow Exhaust retro-fit

Post by Rich »

Did the conversion in Dec. 2006. In best cruise, added 5 knots or so. At high altitude even better. The most noticeable improvement is in climb: 300+ FPM increase (at sea level-ish altitudes) to what is already a good climber. With an MT prop, I didn't have to ante up for a new one. Got the cowl mod done fairly inexpensively by a guy that worked with composites in his real aircraft maintenance job. You do want to arrange for that. I now have a mechanic who is real conversant with this system and is also a big proponent. He's got it down for re-lubing those pipe joints without pulling the system from the airplane.
2002 DA40-180: MT, PowerFlow, 530W/430W, KAP140, ext. baggage, 1090 ES out, 2646 MTOW, 40gal., Surefly, Flightstream 210, Orion 600 LED, XeVision, Aspen E5
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Re: PowerFlow Exhaust retro-fit

Post by Kai »

Can only confirm that the retrofit brought quite a boost in performance. As my DA40 was equipped with a fixed pitch prop, I also had the prop re-pitched at the same time. Total gain was around 10 kts.
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Re: PowerFlow Exhaust retro-fit

Post by Sandy »

To those of you who expressed performance benefits in the nature of higher speeds, can you provide the before/after cruise speeds? I do not have the Power Flow exhaust, but I consistently cruise at 142 kts. Looking at FlightAware charts for the N numbers of your planes I am not seeing anything faster, so please let me know your actual numbers.
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Re: PowerFlow Exhaust retro-fit

Post by Rich »

Before PF, my best at 75% was 137, which is right on book. After, 142-143. I do not always cruise at 75% when just putzing around.
2002 DA40-180: MT, PowerFlow, 530W/430W, KAP140, ext. baggage, 1090 ES out, 2646 MTOW, 40gal., Surefly, Flightstream 210, Orion 600 LED, XeVision, Aspen E5
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Re: PowerFlow Exhaust retro-fit

Post by Ultrapilot1 »

I did the conversation back in June and then flew a 6000nm trip. Before I maxed out at 135kts. Now....141-143!
No change in fuel consumption. Where you really notice is on climb out. I had a passenger recentask me if i had a turbo because you can feel the “push”.
Fuel consumption on climb is 12-1/2. I am seeing 2600rpm. Cruise-9.6 at 2350 square.
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Re: PowerFlow Exhaust retro-fit

Post by astaib »

Hello,

Just some questions, because I never heard about this kit before, and interrested to fly faster with my 2001 DA40.

-Is this kit available in Europe?
-What is the brand?
-Is it in accordance with Lycoming?
-Is it in an OSB from Diamond?
-Will the engine suffer more?

I'm afraid to ask this to my mechanics because I don't want him to say that I'm tuning my airplane as a moped!

Thanks.

Arnaud.
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