Day 195

Today we installed the exhaust pipe. We ground the welds off that attached the shield to the straight pipe on the Rotax motor. We then cut off the straight pipe 32.4mm from the muffler as dictated in the instruction manual. This was a bit trickier because that length is behind the muffler shield. So only half of it could be cut with a standard cut off discs. Unfortunately I don’t have a muffler cut off wheel, (yes they make a tool for that… haha) but we did have a Dremel tool that had some small discs that were able to get the job done.

Once all the pipes were cut we cleaned up and smoothed all the edges. We then mounted the curved pipe and using the clamps provided in our kit bolted it on.

We then fit our cowling back on and traced out a portion that will need to be trimmed to allow it to sit properly. While fitting the cowling we also noticed we needed to move one of the clamp bolts to go the other direction for a better fit. However, when we went to back the nut off the bolt snapped. Not sure if the lock nut was designed to not come back off or not. So we will have to find a replacement bolt for it. In the meantime, we will still be able to finish trimming out the cowling now that the exhaust pipe is at least mounted on the muffler.