PowerFlow Exhaust retro-fit

[Rich]

Powerflow is the company. Check out their website. They make custom variants for a number of aircraft, mostly 4-cylinder Lycoming powered. It has no observed effect on the life of the engine.

[Ultrapilot1]

Arnaud: Go to: https://www.powerflowsystems.com/
In March they received approval from EASA. You will find all the info on their website. They are supplied as standard equipment on DA40's. Everything you need is on the website.

[astaib]

Thanks

[Rich]

A couple of other positives:
1. Lower cowl somewhat easier to R&R
2. Heater works better.

[OliverBucher]

Hello,
I am the owner of the first DA 40 with an officially approved PowerFlow STC in Europe.

Since about one year it is possible to have the PowerFlow STC approved in Europe.

The PowerFlow FAA STC is a "cell STC" and not a engine STC. The FAA has also confirmed with the STC certification that it is a "non Accustic Change".
Due to this fact it is possible to validate the FAA STC for a single aircraft (serial number) at EASA. This costs approx. 300 €.
I can provide the documents for the EASA registration as a scan. It is important that an agreement with Powerflow has to be made before as they have to create a confirmation for the "non Accustic Change".

I am very satisfied with the Powerflow system. At the same time I have also retrofitted an Electroair ignition system at one magnet together with the PowerFlow system.
Altogether my machine is on average approx. 5-7 kt. faster (with same FF). Important at my airfield is the take-off distance. This has also shortened slightly (estimated 20-30m Groundroll). The climbing performance has also improved noticeably.
Also the heat output is much better, which was a disaster with the old exhaust.

The installer of the PowerFlow Exhaust and the Electroair Ignition was Flugzeugwerft Möller in Bonn-Hangelar (Germany - EDKB).

Greetings Oliver

[CFIDave]

The only downside to Powerflow exhaust (besides the cost) is that the STC's Instructions for Continued Airworthiness specifies that ANNUALLY you must remove the exhaust risers and re-install with anti-seize compound applied to the joints. Many mechanics/technicians skip this step since it's not listed in Diamond's DA40 AMM, and owners are unaware that it is required by the STC.

I learned the hard way about this when I owned a Powerflow 2008 DA40: Because this work was not performed, some of the Powerflow exhaust risers developed cracks and had to be replaced.

[astaib]

OK, good information indeed, but I didn't saw the price when I read the first post.

I think that I won't go for this upgrade because of the price...

Arnaud.

[BAA]

Im in the same boat, thinking of doing the mod to my 2005 DA40-180, what cowl mods are required?

[Rich]

Im in the same boat, thinking of doing the mod to my 2005 DA40-180, what cowl mods are required?

The hole where the original exhaust passes through the lower cowl needs to be appropriately patched, as the muffler sticks out through the existing rear gap. The rest of the kit is all bolt-on, and just takes a couple of hours. But you will need assistance in the step where the thing is all assembled and you have to lift it into place onto the exhaust ports. And getting at a couple of the exhaust studs to remove and properly torque is helped by finding a small version of the socket.

[blsewardjr]

When mine was done the hole through which the original exhaust passed was simply covered with an aluminum plate. I had that taken out and the hole patched with composite to make it match the newer DA40's that come standard with the Power Flow exhaust. My experience with my 2003 DA40 has been similar to others -- around 5 kts speed and 100-200 fpm climb increases.