Exhaust system

[G-ARBG]

Wanted: Technical details, photos or patterns of original Nipper MK III twin pipe exhaust system. This system exited the cowling through the aft end unlike the later four vertical downpipe system.

David
G-ARBG

[G-ARBG]

As stated previously I find the standard Nipper MK III exhaust system very noisy causing excessive ambient noise in the cockpit which adversely affects pilot comfort (hearing) and hence radio communication as well as drawing unwanted attention to the aircraft on the ground.
I have now had a set of pipes made as a direct replacement for the pipes on my MK III. The pipes are made from 1 1/2ins dia. thin walled stainless steel tube and simply join front and existing rear pipes together resulting in a weight penalty of only a few ounces in total. Following engine runs on the ground the exhaust note is somewhat less ‘harsh’ and noise acceptability will be further improved when additional ideas from LAA’s Malcolm McBride are incorporated such as perforating and bending the pipe ends. The modification is an attempt to find the simplest, cheapest (and lightest) solution without making any changes to the existing baffles, cowling and heat exchanger / collector. It is my intension to finalise this modification and apply for approval.
However, the system could be much improved if there were an expansion chamber/silencer in the system (see exhaust system on the Sauer installation Trail (page 3 Light Aviation April 2013). This is quite possible to have manufactured uniquely for the Nipper particularly since there is a company (CKT Aero) specialising in small quantity manufacturing who are interested and already supply several light aircraft engine companies with beautifully made stainless exhaust systems. Whether using Lucas mags or Leburg (distributors)the space available is comparable so one system could suit all. Time is money however and whilst I would like to ‘pioneer’ the manufacture of the perfect exhaust system for a VW powered Nipper it requires commitment from at least ten Nipper owners to make it affordable.
I will post photos of progress with my system when the hard disc failure on my computer is resolved.
David
G-ARBG
Look out for CKT at Aero Fair (Friedrickschafen) if you visit.

[jockthenipper]

Hello David, good to hear of your progress with the replacement exhaust. Apologies I have not been over to Watchford to visit you yet as family and work commitments have contrived to deny me the opportunity. Progress on G-CORD is slow but steady at the moment. However, the exhaust system is certainly if interest for the future, anything to reduce fatigue is a good thing. Any estimate of cost if you get enough support to manufacture a batch?

Hope to visit you soon.

Best regards, Peter

[G-ARBG]

Hi Peter,

Thank you for your reply. I will keep you informed of progress and whether there are any further expressions of interest.

Regards,
David