Our Free e-booklet explains it all in simple terms!
The 177 series Cardinal is undoubtedly one of the sportiest looking aircraft in Cessna’s line-up. Unfortunately though, the stock exhaust system Cessna originally installed on the airframe’s legendary Lycoming O-360 engine leaves these otherwise fine aircraft struggling to keep up appearances!
Power Flow offers you the perfect, cost-effective solution to this problem: Our “Bolt-On Horsepower” Tuned Exhaust System adds an immediate 10 - 15 Horsepower to the O-360’s output by virtually eliminating the loss caused by the restrictive design of the aircraft’s stock exhaust system.
Here’s what you can realistically expect from that extra horsepower:
An increase of 30 – 130 rpm in static thrust
A take-off roll that is 100’ to 300’ shorter
An improvement in the aircraft’s rate of climb by 100 – 150 fpm
Reduced Fuel Burn (.5 – 1.5 gph) at your current cruise speed OR –
(for aircraft equipped with a Constant Speed Prop) an increase of 5 – 7 knots in Cruise Speed.
CHT’s that are 15O – 30O cooler across the board.
A Service Ceiling that is 2,000’ – 5,000’ feet higher, with a corresponding improvement in performance at higher density altitudes
Don't just take our word for it - listen to what just some of our happy Power Flow customers have to say about the Power Flow tuned exhaust system on their Cardinals:
So, if you like your Cardinal’s sporty good looks, ease of entrance, and handling, but could stand to be a little more pleased with its performance, you will find our Tuned Exhaust to be a very cost-effective and impressive upgrade.
The Power Flow is a versatile, quality constructed, complete replacement of your entire exhaust system. The entire system is constructed of 321 grade stainless steel and includes minimal structural welds in the cabin heat section for improved safety.
All necessary parts are included for easy installation on your Cardinal. Our customers report an average install time of between four and seven hours. The system can be installed by one of our dealers, by your local A&P, or you can fly your plane to us for a local installation. Fly in with a standard Cessna 177B Cardinal, fly out (usually the same day) tuned for performance.
Our industry leading 60 day money back guarantee means that if for some reason the performance benefits listed above fail to materialize on your Cardinal, you can return the system to us within 60 days of its installation for a full refund of your purchase price. Fine Print? You just read it.
Price for C177B (Classic or Short Stack Configuration) with Lycoming O-360 Engine:
$4,650.00 with Polished Tailpipe / $4,850.00 with Ceramic Coated Tailpipe.
The Classic is our original design from 1999. It is the “ideal” tuned length for this engine. Everybody loves the performance, only a mother (or an engineer) could love the looks.
So, we came up with a compromise: The Short Stack is virtually indistinguishable from the stock Cessna exhaust and will give you about 85% - 90% of the performance gain of the Classic in a much more attractive installation.
If you frequently fly in high density altitude environments, or simply want the biggest possible “Bang for the Buck” we still recommend the Classic. Otherwise, you will be well-pleased with the performance boost you get from the Short Stack.
Polished or Ceramic?
The Ceramic Coated tailpipe is a cosmetic enhancement that hides the heat induced discoloration that is characteristic of stainless steel (think of the "bluing" you see on the muffler of a motorcycle).
This discoloration has absolutely no effect on performance or reliability but the ceramic coating covers it up permanently. Otherwise, the polished tailpipe begins to discolor after a few hours of flying time.
It can be re-polished anytime, but if you are proud of your Cardinal’s appearance and would rather spend your time flying than polishing, the ceramic is a nice feature to have.
Challenger Air Filter:
The Challenger air filter replaces the disposable foam filter media found on most aircraft with K&N's high efficiency reusable filter media which provides up to three times more air flow to the intake manifold of the engine. Our own flight testing has repeatedly confirmed Challenger's published data:
#1.) A definite boost in manifold pressure (up to ½ inch);
#2.) An increase of 1 - 2 knots in airspeed;
#3.) An increase in available power on takeoff.
As mentioned above, the filter media itself is reusable. You just clean it and recharge it (coat it with oil so the dust sticks to it) once a year during annual and you can reuse it up to 25 times or 2,500 flight hours.
Since the Challenger system significantly improves the intake side of the engine at a very reasonable cost, we consider it to be the perfect complement to our Tuned Exhaust System which significantly improves the exhaust side.
Designed by Roy Sobchuk and manufactured by Maple Leaf Aviation in Canada, this easy to install fairing is part cosmetic enhancement (streamlines the appearance) and part performance improvement. It slightly reduces the drag of the tailpipe, but more importantly it creates a venturi to improve the air flow through the cowling for better engine cooling / lower CHT’s. The STC and installation instructions are included.
A couple of other important pieces of information:
#1.) We strongly recommend that the aircraft's propeller be dynamically balanced to within 0.2 ips (inches per second) upon installation of the Power Flow System and every two to four years thereafter. If the propeller is dynamically balanced within 25 flight hours of the installation of the Power Flow System and you furnish PFS with copies of the logbook entries confirming this, PFS will extend the warranty on the Tuned Exhaust System from 12 months to 24 months or 500 Flight Hours (whichever occurs first).
Doing so every 2 - 4 years thereafter will dramatically improve the useful life and the reliability of every component that is bolted to the engine, including the Power Flow System.
#2) The Power Flow System has no service life limit. It is designed and built to last several thousand flight hours and will quite likely be the last exhaust system you need to buy for your aircraft. As with any high performance system however, it must be maintained properly. Every 500 flight hours or annually (whichever comes first) the four slip joints on the system must be cleaned and lubricated with high temperature anti-seize compound.
Most Customers have this maintenance performed during the aircraft's annual inspection which adds about 2 hours of labor to the inspection. We have had several of our Tuned Exhaust Systems rack up over 4,000 flight hours of trouble free performance (7,000+ flight hours is the current record in a commercial operation) as long as this maintenance is performed as required.
Still not sure if a Power Flow is right for you and your airplane? For complete peace of mind, check out our:
Click the RFG graphic above for more details.
*For more technical information please see "Tuned Exhaust Explained" on our home page.
General Magazine Reviews on the Power Flow Tuned Exhaust
“…Power Flow systems offer among the best bang for buck of any mods we’ve reviewed.” – The Aviation Consumer – Feb. 2009
“There’s very little available on the aftermarket these days providing the same return rate on investment.” – The Aviation Consumer – Feb. 2009
“…we are convinced they have a well engineered product and they have made reasonable performance claims.” – Light Plane Maintenance – Sept. 2008
“…the company’s money back guarantee almost makes it a no-brainer to give it a try.” – The Aviation Consumer – Feb. 2009
“I’m not a test pilot but… even I could tell there was a difference. It was that obvious.” Flying Magazine, August 1999 (click to read)
"Although it’s not free, Power Flow has created the closest thing to free horsepower that we’ve seen.” AOPA Pilot, January 2000 (click to read)
“A rate-of-climb increase of about 20 percent is remarkable – not to mention the safety factor increase when leaving high-altitude airports or climbing through cloud layers.” Private Pilot Magazine, December 2000 (click to read)
“…boosts the Lycoming O-320’s output by at least 20HP, while simultaneously reducing fuel flow and lowering CHT’s. Geez, what a deal.” The Aviation Consumer, May 1999
“At the conclusion of the flights, there was no questions that the PFS had improved both climb and cruise performance.” Plane & Pilot, December 2006. (M20 200hp)
“Upon opening the large boxes, I was immediately impressed.” Cessna Owner Magazine, September 2002.
“This is a quantum leap in climb performance.” Cessna Pilots Association Magazine, August 1999
“In the aircraft industry, you see many “mods” claiming incredible changes to performance. It is refreshing to see one that actually lives up to its performance claims.” Cessna Owner Magazine, September 2002. (click here to read)
“The engine gets a more complete fuel burn. The effect in the cockpit is that it will take less throttle to get the same RPM” Aircraft Maintenance Technology Magazine, March 2005 (click here to read)
Posted 12/04/15: Cardinal Flyers Online Fly-in 2105 - multiple testimonials from C177RG and FG:
Customer Reviews on the Power Flow C-177 Tuned Exhaust System:
"Before and After Tests . All tests done about the same outside temps at the same airport. Take off roll was about 4 seconds shorter Climb rate now over 1100 fpm vs 925 fpm Cruise up easily by 7 knots (and my round trip to Boston yesterday proved it). Fuel consumption reduced by 1.6 gph ( JP fuel flow monitoring) Power level is noticeable and there is only a slight increase in exhaust pipe noise Very, Very, Very satisfied as I feel I now have 200hp performance on a mid-time O-360 180hp motor !!" Paul Valois - C177B (O-360) South Burlington , VT
"WOW! The rate of climb was much improved. The exhaust note changed. It now sounds like the HOT ROD that it is." William Butler - Mundelein, IL C-177A (O-360)
Sounds different, better acceleration and climb. I saw an average of 100-150 FPM improvement in climb. Alan Valenti - Bend, OR C-177B (O-360)
Appearance is GOOD. IT IS A DIFFERENT PLANE! James Kellum - Pinson, AL C-177A (O-360)
I love it a "10", I thought the excelleration was greatly improved. After several hours of flying I have noticed about a 150 FPM increase in climb performance and about a 100 RPM increase above redline at full throttle! I live in Georgia and it is hot and humid. So, to get an increase of 150 FPM on a 90 degree day is GREAT. I can't wait to see the difference when it starts to cool off down here. Glenn Sikes - Hoschton, GA C-177 (O360)
* Exhaust Kits have a normal lead time of 6-12 weeks, dependent upon our Sales offer. If you need an exhaust immediately, please call or indicate AOG in the “Notes” section of the online order. All other in stock items normally ship within 2 business days of order receipt. Your credit card will not be charged until the order and shipping cost are verified by our Sales Department and confirmed with you.
** Prices are for US and Canadian registered aircraft only. International customers may place an order online and will be contacted by Power Flow Systems, Inc. or a local authorized reseller regarding final pricing.
Power Flow Systems has a 100% customer satisfaction guarantee. If within 60 days from the date of the first flight after installation the customer is dissatisfied for any reason, they can return the system to Power Flow Systems and they will be entitled to a full refund of the purchase price of the system (exclusive of shipping charges and labor) once the system has been received and inspected by Power Flow Systems. Inspection will take place within five (5) days from the return of the system, and an adjustment to the refund amount will be made for any parts missing or damaged. If the original payment was made on a credit card, it will be refunded to the same credit card, if by check, company check will be issued.
The warranties provided by Power Flow Systems, Inc. in this Statement of Limited Warranty apply only to Exhaust Systems you purchase for your use, and not for resale, and not from Exhaust Systems that are acquired through transfer of ownership. Installation and use of the Exhaust System constitutes your agreement with the terms of this warranty. The term “Exhaust System” means a Power Flow Systems, Inc. exhaust system, its upgrades, elements or combination of them. Nothing in this Statement of Limited Warranty affects any statutory rights of consumers that cannot be waived or limited by contract. If you have any questions, please contact Power Flow Systems, Inc.
The Power Flow Systems, Inc. Warranty for Exhaust Systems
Power Flow Systems, Inc. warrants under normal use and service that each exhaust system is 1) free from defects in materials and workmanship and 2) conforms to FAA regulations where applicable. The warranty period for an Exhaust System is a specified, fixed period commencing on the Date of Installation. The date on your log book entry is the Date of Installation unless Power Flow Systems, Inc. or the Reseller informs you otherwise.
If an Exhaust System does not function as warranted during the warranty period, and Power Flow Systems, Inc. or your Reseller are unable to either 1) make it do so or 2) replace it with one that is functionally equivalent, you may return it to your place of purchase and your money will be refunded.
Extent of Warranty
The warranty does not cover the repair or exchange of a Power Flow Systems, Inc. exhaust system resulting from misuse, accident, modification, installation errors, unsuitable physical or operating environment, improper maintenance by you, installation not performed in accordance with our current and approved installation instructions or failure caused by a product for which Power Flow Systems, Inc. is not responsible. Power Flow Systems, Inc. reserves the right to deny any warranty claim.
THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OR CONDITIONS, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THESE WARRANTIES GIVE YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM JURISDICTION TO JURISDICTION. SOME JURISDICTIONS DO NOT ALLOW THE EXCLUSION OR LIMITATION OF EXPRESS OR IMPLIED WARRANTIES, SO THE ABOVE EXCLUSION OR LIMITATION MAY NOT APPLY TO YOU. IN THAT EVENT, SUCH WARRANTIES ARE LIMITED IN DURATION TO THE WARRANTY PERIOD. NO WARRANTIES APPLY AFTER THAT PERIOD.
Items Not Covered by Warranty
Power Flow Systems, Inc. does not warrant Exhaust Systems where end-users attempt to extract a Power Flow exhaust system from a third-party consumer. End-users, who chose to do this, do so at their own risk.
Power Flow Systems, Inc. Exhaust Systems may or may not fit once removed from the aircraft for which it was originally intended.
Power Flow Systems, Inc. does not warrant any outside labor costs associated with the installation, removal, inspection, repair or other considerations of the Exhaust System.
Any technical or other support provided for a Power Flow Systems, Inc. Exhaust System under warranty, such as assistance via telephone with “how-to” questions and those regarding Exhaust System set-up and installation, will be provided without warranties of any kind. Ultimately, it is the responsibility of the installer, A&P with inspection authority or equivalent, to determine the airworthiness of the installation in accordance with FAA regulations.
If during the warranty period, the Power Flow Systems, Inc. Exhaust System is not in good working order, Power Flow Systems, Inc. will, at its sole discretion, repair or replace it at no additional charge, provided that:
the vibration level of the engine and propeller does not exceed 0.2 IPS at a minimum of 2,000RPM (confirmed by a dynamic balance).
the Power Flow Systems, Inc. Exhaust System is installed on an airworthy engine.
the exhaust is in compliance with our Instructions for Continued Airworthiness Instructions (ICAW).
the Power Flow Systems, Inc. Exhaust System is installed on the designated aircraft it was purchased for.
During the warranty period, if warranty service is required, you may be required to acquire a dynamic balance for further investigation.
To obtain warranty service for an Exhaust System, contact Power Flow Systems, Inc. directly within thirty (30) days of defect discovery. Failure to do so and/or using a third-party for repairs or service will void the warranty. You may be required to present proof of purchase and log book entries. You are also responsible for returning the defective Exhaust System or Exhaust System component to Power Flow Systems, Inc. at your cost. Power Flow Systems, Inc. will not reimburse these shipping costs or any outside labor costs that may be associated with the installation, removal, inspection or repair of the Exhaust System.
Power Flow Systems, Inc. will pay for the outbound shipping expense (UPS ground or other non- expedited freight service) from our facility to the customer, but will not pay for shipments inbound to our facility for warranty repair.
1 Year or 500 Tach Hours whichever comes first.
Power Flow Systems, Inc. parts, Power Flow Systems, Inc. labor and shipping replacement to customer only.
Limitation of Liability
NEITHER Power Flow Systems, Inc. NOR ITS SUPPLIERS SHALL BE LIABLE FOR INCIDENTAL, CONSEQUENTIAL, INDIRECT, SPECIAL, OR PUNITIVE DAMAGES OF ANY KIND, LOSS OF INFORMATION OR DATA, OR OTHER FINANCIAL LOSS ARISING OUT OF OR CONNECTION WITH THE SALE OR USE OF THIS PRODUCT, WHETHER BASED IN CONTRACT, TORT (INCLUDING NEGLIGENCE) OR ANY OTHER THEORY, EVEN IF Power Flow Systems, Inc. HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. Power Flow Systems, Inc. ENTIRE LIABILITY SHALL BE LIMITED TO REPLACEMENT, REPAIR, OR REFUND OF THE PURCHASE PRICE PAID, AT Power Flow Systems, Inc.’s OPTION.