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Old 11-21-2015, 07:45 PM
Taildrgr's Avatar
Taildrgr Taildrgr is offline
Join Date: Jun 2011
Location: DFW Area, TX
Posts: 229
Default Exhaust Hanger Broken

During my preflight I grab the exhaust extension below the cowl exit and give it a good shake.

At 16 hours into Phase I, my right pipe was loose.

Looking into the cowl exit with a flashlight showed a broken exhaust hanger.

My hangers are connected to the engine sump so the exhaust moves with the engine.

I called Clint at Vetterman Exhaust and he said the hanger tubes can break if they are bent for fitting during installation.
As can be seen in the pics, mine is not bent.
Clint also said they have had some rare breaks for unknown reasons, perhaps a defect in the crimped end.

I think I will move the cross piece up a bit to make sure it does not rub on the nose gear mount.

Anyway, I replaced the hanger tube and will continue checking them during preflight.

Just wanted to give a heads up to all about checking those exhaust hangers.

I put the hanger back together for this picture.....
Bob B
RV-7A Sold
RV-4 Sold
Dues Paid
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Old 11-21-2015, 07:51 PM
Kyle Boatright Kyle Boatright is offline
Join Date: Aug 2005
Location: Atlanta, GA
Posts: 4,677

The components in the exhaust hangar system break frequently. I carry a spare set in my fly-away kit.
Kyle Boatright
Marietta, GA
2001 RV-6 N46KB
2019(?) RV-10
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Old 11-21-2015, 09:18 PM
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Infidel Infidel is offline
Join Date: Sep 2011
Location: WV22
Posts: 849

A little jiggle on the exhaust pipes is always a part of my preflight and glad to see others (you) doing it as well.
RV-4 0320\D3G 160, Whirlwind 200GA 70".
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Old 11-21-2015, 09:45 PM
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LifeofReiley LifeofReiley is offline
Join Date: Jan 2005
Location: Round Rock, TX
Posts: 3,779

It does happen, a lot going on in this area.
Retired N622DR - Serial #V7A1467
VAF# 671
Repeat Offender / Race 007
Friend of the RV-1
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Old 11-21-2015, 10:22 PM
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Sam Buchanan Sam Buchanan is offline
been here awhile
Join Date: Dec 2004
Location: North Alabama
Posts: 4,466
Default Been a problem for as long as RVs have had exhaust systems

Been flying my RV-6 for 16 years and broken exhaust hangars were a known issue when my plane was new. I carry a length of steel automotive brake line in the flight kit so a new hanger can be fabricated on short notice. Fortunately a broken hangar usually won't keep you from flying the plane home.
Sam Buchanan
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Old 11-21-2015, 10:24 PM
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az_gila az_gila is offline
Join Date: Jan 2005
Location: 57AZ - NW Tucson area
Posts: 10,011

Originally Posted by Kyle Boatright View Post
The components in the exhaust hangar system break frequently. I carry a spare set in my fly-away kit.
That's a good case for installing the bolts in a "backwards" from standard fashion with the nuts facing out.

Would make a replacement easier with less clamping tools involved in the field.
Gil Alexander
EAA Technical Counselor, Airframe Mechanic
Half completed RV-10 QB purchased
RV-6A N61GX - finally flying
Grumman Tiger N12GA - flying
La Cholla Airpark (57AZ) Tucson AZ
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Old 11-22-2015, 07:14 AM
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Taildrgr Taildrgr is offline
Join Date: Jun 2011
Location: DFW Area, TX
Posts: 229

Hopefully, this won't be a recurring problem every 16 hours, but I did order 2 extra hanger pieces from Clint just in case!

It only took about 20 minutes to change it out.

Good idea to put one in my travel kit for long x-cntry's.
Bob B
RV-7A Sold
RV-4 Sold
Dues Paid
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Old 11-22-2015, 07:29 AM
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turbo turbo is offline
Join Date: Jan 2007
Location: Stuart, FL /Hartford, CT/Virgin Gorda,BVI
Posts: 3,176

I replaced all of my with pieces made out of solid steel. I flattened out the ends of the steel rod and now have a bullet proof system that will never brake.
TURBO YES =VAF= Payed Jan2021
Ed D'Arcy
RV6-A 5,300+ hrs, R-44 1,600 hrs, Helicycle traded for 33 FFR coupe, 300 young eagles flown
Stuart, Fl / East Hampton,Ct / Virgin Gorda, BVI - villa sold.
addicted pickle ball player
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Old 11-22-2015, 12:16 PM
posterman posterman is offline
Join Date: May 2007
Location: Redding, CA
Posts: 96

I converted my upright tubing running from the exhaust to the back of the sump to very thick walled 4130 chrome moly - required MAPP gas to heat the ends sufficiently well to pound out flats for the breakage in over 450 hours.
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Old 11-23-2015, 06:17 AM
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Steve Melton Steve Melton is online now
Join Date: Apr 2011
Location: Cincinnati, OH
Posts: 3,529

what about a washer between the hangar and bracket to give it more room to move?
Steve Melton
Cincinnati, OH
RV-9A, Tip-up, Superior O-320, roller lifters, 160HP, WW 200RV, dual impulse slick mags, oil pressure = 65 psi, EGT = 1300F, flight hours = 900+ for all

Simplicity is the art in design.
I was born an airplane nut. I have no explanation for it.
My Artwork is freely given and published and cannot be patented.

Last edited by Steve Melton : 11-23-2015 at 10:54 AM.
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