My paramotor exhaust cracked

[boeing7873]

Dear friends,
My paramotor exhaust muffler cracked after a few hours of flight. It is made of steel and is about 1 to 2 mm thin. I have not found anyone that accepted the challenge of welding it again.
I don't even know what welding type is better!
Anyone out there would like to accept the challenge? I am willing to pay a reasonably price for the work, but I need someone with confidence on his/her skills... a new muffler is not only very expensive (about $350), but also very difficult to find as the new engines have been modified, so the muffler is now discontinued!!!
I would appreciate a reply to my email:

jc4045808447@gmail doty comy

(check out my video paramotor video http://www.youtube.com/watch?v=kjsr1DREr70)

 

[Shox Dr]

You'll be luckly to find anyone that would be willing to do such a job, on the cheap I'm more than sure "the welder" will require codes, and some sort of licence to work on Aviation equipment. Good luck

 

[Seano]

You'll be luckly to find anyone that would be willing to do such a job, on the cheap I'm more than sure "the welder" will require codes, and some sort of licence to work on Aviation equipment. Good luck

Wouldn't have thought a exhaust muffler was (real) aviation equipment Shox.... I await to be corrected..

Sean.

 

[wyn]

Is it something like this ?

 

[will123thomas]

theres not much point in welding it because it heats up and cools all the time so it wont last 5 mins. the exhaust on my car completely snapped off at the manifold/downpipe flange when i was away for the weekend, it was the loudest and most embarassing thing ever with the most looks from people ever, i took it into work to get someone who was coded to weld it and they wouldnt, cost me £160 which i didnt have to fix it!!

 

[Woody.v8]

theres not much point in welding it because it heats up and cools all the time so it wont last 5 mins. the exhaust on my car completely snapped off at the manifold/downpipe flange when i was away for the weekend, it was the loudest and most embarassing thing ever with the most looks from people ever, i took it into work to get someone who was coded to weld it and they wouldnt, cost me £160 which i didnt have to fix it!!

Ive welded exhausts that have lasted years, The only time there not worth welding is if you can either buy one cheaper or its dissolved in its own rust, Otherwise i couldn't foresee a problem.

 

[will123thomas]

Ive welded exhausts that have lasted years, The only time there not worth welding is if you can either buy one cheaper or its dissolved in its own rust, Otherwise i couldn't foresee a problem.

well thats what i thought i was gona do it myself but they wer really persistent it wouldnt work, my cousin lived near where i was when it blew and he brought a gasless welder round and i welded up about half way round to do me till i got home, it lasted at first until i was on the country roads coming home then it just snapped off again, only had the car a month at that point

 

[R Kraft]

You might try a shop that makes custom 2 cycle motorcycle exhausts and expansion chambers.
Robert

 

[hotrodder]

Wouldn't have thought a exhaust muffler was (real) aviation equipment Shox.... I await to be corrected..

Sean.

Exhaust repairs need inspection and signing off just the same as an engine mount or landing gear repair. Bad things can happen when bits fall off aircraft

Powered paragliders are generally exempt from the regulations AFAIK but there's still the liability from the welders POV to consider (OP is in the states). Pretty sure my insurance company would laugh in my face if i asked about coverage for aviation welding but wasn't working to the relevant CAA or AWS codes. Physically fixing it is easy enough (1mm isn't exactly thin) but finding someone willing may be tougher. More importantly, why did it fail after only a few hours?

Edit: appears to be a few known problems with this sort of thing

 

[shenion]

Pictures of the damaged area might help.

It may be stainless, try a magnet on it.

 

[Seano]

Exhaust repairs need inspection and signing off just the same as an engine mount or landing gear repair. Bad things can happen when bits fall off aircraft

Powered paragliders are generally exempt from the regulations AFAIK but there's still the liability from the welders POV to consider (OP is in the states). Pretty sure my insurance company would laugh in my face if i asked about coverage for aviation welding but wasn't working to the relevant CAA or AWS codes. Physically fixing it is easy enough (1mm isn't exactly thin) but finding someone willing may be tougher. More importantly, why did it fail after only a few hours?

Edit: appears to be a few known problems with this sort of thing

Cheers for that hotrodder.....

WcW

 

[Rick]

Are you in the US, do you have pictures of the damage?

 

[boeing7873]

To answer a few things..
Powered paragliding, paragliding, hang-gliding, and other light air-vehicles that weight(empty) less than 254 lbs are not regulated by any authority in the US. Working on them is the same as working on your motorcycle.
http://en.wikipedia.org/wiki/Ultralight_aviation
With respect to safety of POWERED paragliders, statistics show much better numbers than motorcycle related accidents. So, if you are concerned about any liability, working on motorcycle parts should be more concerning to you.
The link above to a PG safety related website is a quite unfair way of introducing these sports. It would be equivalent to propose: "Hey guys, take a look at this sport, this is what he is talking about! http://www.motorcycle-accidents.com/pages/stats.html"

I've been flying since 1997 and I did have several mechanical failures of my equipment, usually muffler related, although I had also fuel lines melt, bolts come loose and hit the prop, denting it and unbalancing it. The good news is that engine failures on paramotors do not change your risk, it only shortens the flight. In other words, your glider is not dependent on the engine, it is just like in your motorcycle, if your engine quits, you glide to a stop. Of course, good judgment is a must in this sport. I am a pilot for a major airline and I apply the same principles of risk management when flying my paramotor than when flying 70 people in the jet.

These machines are produced in very low quantities and often there are many iterations of design until the final version is totally reliable. For example, my muffler is of first generation, the newer engines have a different cylinder/muffler coupling design that minimizes the vibrations that generate cracks. but to change the cylinder means another $500.

My muffler is steel, (yes, magnets like it)
I am in Atlanta, anyone willing to give it a try? I will post pictures as soon as I have time.

 

[hotrodder]

Boeing,
Wasn't trying to insinuate that powered paragliders are unsafe, i posted that link simply because it appears that this sort of failure is common. Fatigue cracking of a component that only has a few hours on it suggested to me that there are some design issues to work out- simply weld the cracks and it's likely that it'll soon crack again.

I take your point about liability regarding bikes etc. The way i worded it didn't help but what i was trying to get at was perceived liability if that makes sense. Single cylinder bikes will vibrate many things to bits given the chance, wouldn't think twice about making parts for them. Paramotor may be no different but because it flies insurance company might view it differently- or i could be talking nonsense

Pics would be good, someone may be able to offer advice regarding improving the design. If there any pics available of the new improved design that'd be interesting to see

 

[Rick]

Pic's would help, as above, its more likely a design problem that no amount of welding will permanently fix.