February 2021

Do you ever find yourself in the middle of a project that turned out to be a lot more complicated, time consuming, and daunting than you could possibly have imagined when you first took it on? Well, we have!

And, of course, the first question that comes to mind in situations like that is typically: “Will this all be worth it?”

In the case of our now multi-year project to return the LEES products to production, the answer to that question is perhaps best provided by the first pilot to fly with a new PMCF system as re-engineered and precision fabricated by Power Flow Systems.

Here are my thoughts of the new exhaust...first, I love the sound! I’m a car guy, and it’s sounds like a hot rod ready to race! As far as performance, I can feel the extra power on takeoff and climb. Once at cruise, it actually sounds a little quieter than the stick exhaust. But favorite aspect is the performance and fuel economy. While running ROP I’ve gained a few knots, but I’ve gained the ability to run LOP, at which I have the same speeds that I had ROP with the stock pipes, but now running 2-2.5gph less than previous operations...and I repeat, with no speed loss! We left on a trip to Colorado (from Florida) the day after we completed the installation and profile flights, and the plane ran the best it ever has. I ran LOP for the entire 23+ hours, with great EGT/CHT temperatures, all of which were within 50-75° degrees across the board. The engine was very happy, and I saved over 50 gals of fuel. That cost savings will add up fast! Overall, I am completely satisfied with the new PowerFlow exhaust!! Thank you!

Blue skies,

Mike

Our Engineering team is hard at work correlating the results of the before and after flight tests conducted on -80V and we will publish those results as soon as possible. In the meantime, if you’d like to see and hear the difference the PMCF makes for yourself, we invite you to visit our YouTube video of the first post-installation test flight via the video pictured below:

First Skylane Installation:

We followed-up the successful installation on Mike’s Skywagon with our first installation on a Skylane: N182DL, a 1976 O-470 powered Cessna 182P, owned by Mr. Richard Low.  

This installation was a perfect validation of Power Flow’s strategic decision to conduct the first several LEES installations at our facility in Daytona before beginning serial production and shipments to our Depositors worldwide.

-2DL has a “speed cowling” modification to fare in the upper section of the nose strut. Unfortunately, this configuration presented a challenge as it did not permit the cowling to be shifted aft. Even before the PMCF upgrade, it was already a bit of a challenge to remove and re-install the cowl with the single, original exhaust stack which angles slightly rearward.

Since the PMCF designed tailpipes are oriented down and angled to the rear, it would have been impossible for the modified cowling to be installed as it could not move rearward to get past the tailpipe’s lower angle. (Imagine encountering and trying to resolve that problem in the field!)

Our solution was to create an optional two-piece tailpipe assembly that allows for the straight section to come through both holes in the cowling thus permitting an easier cowling installation. The tailpipe tips are then installed after the cowling is in place. The tips are held into position by a pinned clamp. This allows for maximum flexibility for the installer as the installer can set the rotation angle. 

We believe this solution will accommodate a number of popular modifications that are available and installed in the field. It will also simplify the installation and allow for easier ongoing access when removing and re-installing the cowling.

What do you think? Would you use the optional two piece tailpipe for your installation, or the one piece?

Keeping The Momentum Going:

We are actively seeking additional C180 and C182 models with some of the more common modifications from the original engine/cowling configuration. We are also looking to bring in a C185 aircraft for local installation as that model’s exhaust system is slightly different than the C180 and C182.  

If you have such an aircraft, are one of our depositors, and would like to assist us in making the new LEES products as good as they can be, we would love to hear from and work with you. We are still offering to completely install your new PMCF system at our facility in Daytona Beach (not a particularly bad destination during these cold winter weeks), for the reduced flat rate of $800.00.  

As each of these installations is likely to present issues similar to those outlined above, we ask that you be prepared to leave your aircraft with us for up to one week. This gives you plenty of time to enjoy the sunshine and sandy beaches and gives us plenty of time to address and resolve any fit and function challenges that may arise.

Once each model specific configuration (such as Seaplane West engine mounts, Speed cowl, etc.) is cleared by our Engineering team, we will contact our deposit holders with our planned ship date in the order in which their initial deposits were received.  

At this point we anticipate an average of 4-5 exhaust systems will be shipped or installed locally each month for the next 2-3 months. This rate will increase as each different configuration is cleared for production.

Further Down The Road:

Early C180, Cessna 200 series and PA12/18 series:

We haven’t forgotten about you! Our Engineering team continues to work on the drawing to part conformity for all 3 of these additional product lines. Our goal is to get FAA PMA approval on all of these systems as rapidly as possible so that we can support the existing customers with replacement parts. Full scale production will follow shortly thereafter.

Here is a pic of the Engineering office as we are mapping out the Super Cub drawing “puzzle”:

We will continue to keep you posted on our progress through these newsletters. In the meantime:

Blue Skies, Tailwinds, and –

All The Best!

View the original newsletter here.