Better with the sound off, IMO.

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Just what constitutes a "Vintage 777"? Aren't the oldest ones less than 20 years old?? I still think of them as relatively new!! lol.. (of course, we are still taking deliveries of brand new ones, maybe that's why..)

This one was line number 422, delivered 2002. Total Time Airframe 76039:21, Total Cycles: 11046

On approach to Naval Air Station, Guam. 1966.
http://forums.pelicanparts.com/uploa...1570989926.jpg

Flying from Chicago headed back to Florida. Of coarse I’m over a solid overcast with 800’ ceilings. I hear a noise and slight vibration. I diverted to the nearest VFR airport that was about 30-40 miles away and kept my eyes on my engine gauges. Nothing seemed out of wack, but I was definatly hearing something and it felt out of balance.

The wife was terrified, she’s a nervous flyer as is.

After landing in Indiana I found this.http://forums.pelicanparts.com/uploa...1571652713.jpg

I was able to use a loaner car to drive the wife to Indianapolis and catch a flight home. I’m staying and hoping to get a new exhaust manifold located and installed ASAP. This happened on Sunday, so today I’ll be on the search.

Yikes. That is some exhaust leak. Is the cabin sealed well enough to keep any carbon monoxide from seeping in?

dmcummins: I'm guessing that the engine had been running a bit too lean and the very hot exhaust gasses melted down a hole in the manifold. What engine? Lycoming? Continental? Engine size?

The Engine is a IO-470 Continental. It’s the original 1960 engine, it’s been overhauled several times. I don’t know how old the exhaust is.

Honestly it was a little wavy and obviously very thin.

I have a CO monitor and it didn’t alarm and I didn’t actually look to see if it was showing high numbers. I was just looking for the nearest airport with higher ceilings to land at.

You did a nice job, DC.

Any anomaly above the clag gets your attention and you did all the right things.

yep, detected something not right and made the right decision to get on the ground.

and since you will most likely be replacing the entire exhaust system, you could consider headers. Maybe these folks at https://www.d-shannon-aviation.com/bonanza-exhaust.html can help you out with a header system. Gain a bit more HP and maybe better fuel economy.

http://forums.pelicanparts.com/uploa...1571666585.jpg

But first you need a manifold to get you home. Or weld a patch over the hole? Will that work and get signed off?

I have a new exhaust coming hopefully tommorow. Cost is $615 for the exhaust, $30 for gaskets, and I don’t know what the overnight air cost will be.

And the local IA to put it on and sign it off.

I was thinking a couple of beer cans and hose clamps and I would be good to go.

They would have to be the old school beer cans that were much thicker than today's beer cans. Maybe some steel soup cans instead? That area of the manifold gets direct impingement of the exhaust from two cylinders and gets really hot.

Is there an FBO at the airport where you landed? And can they weld? An airplane salvage yard nearby? A Beech Debionair on the ramp you can "borrow" a manifold from?

I have a new one that’s supposed to be shipped out today, overnight air.

I checked around and no one close had one. The metal is pretty thin there, not worth the trouble to weld on a patch,. I’m still a 1000 miles from home, I don’t want to take a chance on a patch. If I could even find someone to do it.

At least they had a cool courtesy car.

http://forums.pelicanparts.com/uploa...1571675782.jpg

Shoulda posted here instead of seperately
 

Restoration of a WWII era bird I'd never heard of. XP82

https://www.youtube.com/watch?v=WQP0IHH3FTs&feature=youtu.be

A few years ago the exhaust manifold of my IO-550 started bulging in that same area.
Glad we found it during the annual inspection vs. while in the air.

I considered switching to headers at that time, but my mechanic discouraged that.
No real performance gains (550 provides plenty of oomph), more heat in the engine compartment, and more difficult future maintenance with the extra space needed for the headers.

We installed a new stock manifold and lived happily ever after.

This would be a great ad for that black tape stuff that is supposed to seal anything! Ha ha..

Found this story and knew all you guys could relate...


https://www.popularmechanics.com/flight/a29417998/cessna-badass-plane/