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Ken/Buly,
The Mazda's high heat has proven to cause cracking at the joint of the exhaust flange to the exhaust pipe UNLESS there is room to expand and contract due to the heat cycling. Welding the inside and only having four tack welds of a reasonable length, have proven to be satisfactory and better than full welding inside and outside the flange.
There are other methods which separate the pipe from the flange - such as the motorbike style fitting, where you have a small round tapered flange which is captured by the larger flange( clamping action), as it is bolted up. This would be my preferred style of fitting, which would completely eliminate the pipe cracking problem. The muffler would need to be supported independently, which is the preferred method anyway.
George ( down under)
On Oct 9, 2006, at 11:15 PM, kenpowell@comcast.net wrote:
Hi Joe,
Just a heads up - it looks like your new "header flange to pipe" (picture 5) was welded on the outside. I think that 'acceptable practices' state that there should only be a tack weld on the outside and the actual structural weld should be on the inside. What does everyone else say? In any event be sure to keep an eye on the welds.
Ken Powell
Bryant, Arkansas
501-847-4721
C150 / RV-4 under construction
Ken, I had the chance to inspect hundreds of aircraft exhaust systems from C-150 to the big twins. On 99% of them the flange is welded on the outside. I have seen only one model aircraft that requires welding on the inside only?
Buly
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