Bolt-On Horsepower     /     Complete replacement of your exhaust system:

The 177 Cardinal series is undoubtedly one of the sportiest looking aircraft in Cessna’s line-up.  Unfortunately, the original exhaust system designed by Cessna 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 output of either the O-320 or the O-360 by virtually eliminating the power 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 15 – 30 degrees cooler across the board.

• Exhaust Gas Temperature (EGT) extremes reduced between cylinders

• A Service Ceiling that is 2,000’ – 5,000’ feet higher, with a corresponding improvement in performance at higher density altitudes 

• No welds in cabin heat area practically eliminating the possibility of Carbon Monoxide poisoning

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 177 Cardinal, fly out (usually the same day) tuned for performance.

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:

*   Exhaust Kits have a variable lead time, dependent upon our Sales offer and manufacturing capacity - Please refer to the chart below for current lead times and any available discounts.  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. 

Polished finish Classic Tailpipe show below.

“Classic” Tailpipe or Short Stack Tailpipe? 

The Power Flow System is available in two basic configurations for the Cardinal: The original “Classic” (Long Tailpipe) version and the newer “Short Stack”.  The Classic version does give the biggest performance boost, but the difference is usually only noticeable if the aircraft is routinely operated in high density altitude environments (7,500’ and above).  This version also facilitates Lean Of Peak operations for even greater fuel efficiency. 

The Short Stack system provides about 90% - 95% of the performance increase that is possible with the Classic system with a less "distinctive" installed appearance.  It also makes removing & re-installing the cowl a little easier and about 5 - 10 minutes faster. 

Polished Finish or 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 Cessna's appearance and would rather spend your time flying than polishing, the ceramic is a nice feature to have. 

Original Classic Tailpipe

Short Stack Tailpipe

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.  Power Flow's Testing of the Challenger Aviation air filter is a great complimentary product to the Power Flow tuned exhaust. We conducted our own tests to justify claims on this product and our results were as follows:

• Definite boost in MAP

• Increase of 10-15 RPM

• More power generated on take-off

• Engine was able to "breathe" better

Challenger Aviation Advertised Benefits:

• Increased horsepower

• Increase in RPM or Manifold Pressure

• Reported fuel savings of .3 to .5 gallons per hour

• Uses K&N re-cleanable air filter media

• Up to 50% more air flow with the same dirt holding capability

• NO AD's

• Installs into factory location

• Up to 25 recharges or 2500 hrs

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 your Cessna's 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.

Maple Leaf Exhaust Fairing

Part cosmetic (streamlines the appearance) and part performance, this optional 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 and lower CHT’s.  The kit comes complete with the STC, all installation hardware, spacers for test fitting and simple Installation Instructions.

Product Brochure - Click here to download  

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: 

Power Flow Systems Warranty Details.

Warranty

Every Power Flow Tuned Exhaust System comes with an unconditional 60 day (from time of installation) money back guarantee. If you are not totally satisfied, for any reason, you can return the system for a full refund of your purchase price.

Power Flow strongly recommends that a Dynamic Propeller balance be performed on the aircraft in conjunction with the installation of the new Tuned Exhaust System.  If the propeller is dynamically balanced (vibration lower than 0.20 IPS at a minimum of 2000 RPM) within 25 flight hours of the installation of this 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.