Bolt-On Horsepower. Perhaps no other single in Cessna’s line-up of iconic aircraft inspires as much fanaticism among its Owners and Pilots as the Sleek and Stylish Cardinal RG. Our well-proven Tuned Exhaust System (now installed on nearly 20% of the entire U.S. Fleet!), gives your bird the performance to match its exciting looks!
Our Free e-booklet explains it all in simple terms!
Make your Cardinal a faster, higher flying bird. Similar technology has been used in race cars and motorcycles for years, now it is available for your Cardinal RG. By more effectively emptying the cylinders of spent exhaust gases, our Tuned Exhaust
System immediately gives your RG the following improvements:
5 -7 knots faster cruise speeds
10% – 15% increase in rate of climb
0.5 – 1.5 gph reduction in fuel burn at equivalent airspeed
Improved Take-Off Performance (100’ – 300’ reduction in ground roll)
Increase in Service Ceiling of 2,000’ – 5,000’
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 177RG 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 RG, 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.
List Price for C177RG with Lycoming I/O-360 or I/O-390 Engine:
$5,400.00 with Polished Tailpipe / $5,600.00 with Ceramic Coated Tailpipe.
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 RG’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)
Customer Reviews on the Power Flow C-177RG Tuned Exhaust System:
“In my airplane the Powerflow provides substantial benefits in takeoff and climb and a truly remarkable increase in speed. It turns the Cardinal RG into a noticeably different airplane. I'm looking forward to having the extra performance available in short fields, at high altitudes, under heavy loads and on hot days. And the extra cruise speed and/or efficiency won't be hard to take either!” K. Peterson, Cardinal Flyers
“The fuel flow is dramatically improved, speeds (TRUE) are improved, and the engine runs cooler.” P. Fisher, WV
“...I do like it, I’m getting impressive numbers. ...I do appreciate the after sales support – very professional and again, I encourage anyone to try Power Flow – they won’t be disappointed.” L. St. Hilaire, AB – Canada
"A PowerFlow exhaust was installed on my RG last week, and I was amazed at the difference it made! Acceleration and climb were dramatically better, and cruise was somewhere between 5 and 7 knots faster. With two full-sized guys aboard as passengers and full fuel it performed like it used to with only me aboard. I had been worried that the exhaust note would be annoying, but it's actually rather enjoyable - more of a confident snarl during takeoff than a hum. When I bought my RG over two years ago, I accepted that it wasn't as frisky as other Cardinals I had flown because its engine was close to TBO. But the Power Flow exhaust has rejuvenated it. In fact, I was having so much fun flying it that I spent a lot of money on avgas over the weekend! " J. Peck '77 RG N52044 at Paine Field, Everett, WA
"...my new powerflow exhaust has been installed on my Cardinal RG and I couldn’t be happier. My speed improvement seems to be about 8 kts with slightly higher fuel flows. Matching book speeds, I seem to be able to save about 0.6 GPH. Quite impressive performance. Installation was very straightforward and it fit like a glove. Excellent product! J. Jeans '71 177RG
“The extra power on climb out with my new tuned exhaust is quite excellent. Next to a turbo conversion, the PowerFlow is the most significant modification to improve the performance of the C177-RG. I have nothing but good things to say about your company. Thanks again!” A. Petropolis '78 177RG
"For anyone considering Powerflow but undecided. I have had it installed on my RG since late spring and couldn't be happier with it. I won't say the performance increases will pay back the purchase price in the short term, but the emotional high from having a plane that performs so well on such a small fuel burn is very satisfying. In addition, the ability to carry a full load out of short and/or higher fields on a hot day and the added safety when operating high, heavy or hot makes it worth the investment to me.I'm not suggesting anyone exceed the operating limits of the plane, just that this mod gives the plane the performance that it should have, and maybe a little more. Consistent 148 to 150 knots true on 10 gallons per hour and up to 154 on 11+.Best rate climb lightly loaded in excess of 1100 fpm even on the hottest days. Much more on cool days. Full load hot day climbs of 800 to 900 fpm with better in cool weather. Cruise climb sustained at 500 fpm on a hot day to 8000 ft. fully loaded. Quite a bit more if light or cool.I apologize that these are general numbers rather than actual test results. My intent is only to say that the PowerFlow met and possibly exceeded my expectations. An added plus is that Tyler, Darren and all the other folks at PowerFlow are great. B. Wallen '76 RG
Hey PowerFlow folks, I finally had a chance to really test out the cabin heating capablities of your system for the Cardinal RG. Last Sunday with air temps around 10F on the ground and 5F at 6500', my cabin was nice and toasty. I was comfortable in just shirt sleeves. Best part was the cabin heat was much better on the ground during taxi and takeoff. My PF exhaust works much better the stock (but you guys knew it would). Thanks. B. Hutchings
This is an excellent product. I recommend it highly to all my pilot friends. There is a noticable improvement in climb performance, especially at higher density altitudes. A. Petropolis '78 177RG
* 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.