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One of the things I remember about reading Kent Passer's book "Speed
with Economy" was that he trimmed his exhaust stack so that the end
of the exhaust was effectively right where the air exits the lower cowl.
This has the effect of ejecting the cooling air at a greater velocity
and hence eliminating a very small amount of cooling drag. Has anyone
done this with an RV?
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Been there, done that; RV-6, O-320.
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I wonder if this would help with CHT cooling.
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I noticed no difference in CHT's.
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How much louder would the exhaust note be in the cockpit.
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Definitely louder.
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Would the floor boads rattle your legs off?
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Won't rattle your legs off, but you will feel more vibration. You are also treated to the frequent chore of cleaning lead deposits off the bottom of the plane.
After a couple of years of flying with the shortened stacks, I finally got around to ordering a set of turndowns from Larry Vetterman so I could correct my moment of madness.
In my opinion, chopping the stacks has no benefits; keep the hacksaw in the toolbox.
(I was, however, able to convince my hangarmate that my plane was four knots faster than his.

)
Sam Buchanan