Chabord Creates Lightweight Aircraft Headers For Popular Engines

Automotive performance enthusiasts have appreciated the benefits of tuned exhaust systems for decades. By optimizing the timing of the arrival of exhaust gas pulses from the various cylinders at the collector, and sizing individual tubes for the desired power band, a properly designed set of headers can be a very cost effective, bolt-on modification for aircraft owners seeking better performance and fuel economy.

 IO540/580 System

Aftermarket performance exhaust systems for aircraft engines are not new, and can be installed under STC. What is new about the headers designed by Chabord High Performance Manufacturing is their weight. At AirVenture Friday, Chabord displayed a tuned system for the Lycoming 540- and 580-cubic-inch engines used in air racing which its says weighs just 4 kg (8.8 lb), including the collectors. Another system (below) designed for the Lycoming 360 CID engines in a Vans RV-8 cowl includes a muffler, yet claims a weight of just 7.5 kg (16.5 lb).

 RV-12 System & Muffler

Both systems are constructed of 316L stainless steel with some parts made from 625 Inconel sheet. The materials are chosen for temperature resistance, and joints feature shoulders at weld points and rolled lips at pipe outlets for strength.

Chabord, which calls its header product "Eco-Exhaust," reports a customer's RV-8 with a 200-hp Lycoming IO-360 improved by 10 percent in fuel consumption (comparing identical missions), five knots in cruise speed, and was 3-10 dB quieter depending on frequency. On an already optimized high performance aerobatic competition aircraft powered by an IO-540, takeoff and climb performance reportedly improved five percent.

Chabord has EASA STCs for a variety of popular aircraft with powerplants including TCM, Lycoming and Rotax models, and says it can provide custom tuned exhausts for any engine. Prices were not specified at AirVenture.

As a demonstration of the company's precision welding capabilities, Chabord is displaying a complex titanium part (shown on finger) which doubles as an engine mount and pressurized oil reservoir in a race car, yet weighs just ounces.

FMI: www.echappement-chabord.fr/index.php?lang=en