Custom Exhaust Systems-
Crossover Exhaust

Crossover with tailpipes and heat muffs	Crossover with mufflers and heat muffs

Aircraft Exhaust Inc. has standard crossover systems that fit many different applications of aircraft with Lycoming 4 cylinder engines. Lycoming engines are the only manufacturer that sees a gain from the savaging effect of a crossover. The crossover is a good system for the money. It is more expensive than single side stacks but it is quieter and has more area for cabin heat. The HP output is more than a single muffler or a single stack style with muffler.

The crossover is a different system that fits the tightest cowls. They are quieter than the single side stacks due to the length of tubing between each cylinder and out to a long detachable tailpipe or muffler. The tailpipe is attached using a ball joint on the crossover and a bell joint on the tailpipe with back up rings, bolts, springs and nuts same with the muffler system. The tailpipes and mufflers come with a tailpipe support clamp so a support can come from the engine or airframe to the tailpipe support clamp with a customer supplied cable rubber hangers or other means.

Aircraft Exhaust Inc. builds the cabin and carb heat shrouds from stainless steel to assure that their will be no failures due to the extreme heat from the primary in which it is wrapped around non-muffler system. A carb heat muff is supplied on carburetor engines, it mounts on a tailpipe (but only requires 4-6” of straight). The carb heat has a series of holes which draw air from the engine compartment into the muff as it is pulled past the tailpipe it is heated and is sucked into the carburetor creating a 95+ degree temp rise over ambient (FAA requirement for temp rise for carb heat on certified aircraft). Both the cabin and carb heat shrouds are 3” OD with a port in and a port out. Typical scat size for good air flow is 2”.

If a further reduction of Db’s is wanted or more cabin heat is desired than is available from the 2” tailpipe; this system is designed to be able to add XM or GP mufflers when ever needed.

With the addition of mufflers the heat is drawn directly from them and is an excellent set up for great cabin heat, lower Db, and a good exhaust system. Call our sales team to get more information about your application or to place your order.

The standard crossover system that we supply off the shelf is for the 4 cyl Lycoming and crosses over just forward of the air intake or carburetor. If you have a forward facing induction system or offer modifications that do not allow this type of crossover then a PVC kit must be purchased. You can build up out of PVC a working crossover that fits your engine and aircraft. The PVC unit does not have the same price as our standard crossover. The standard crossover has a lower cost due to the pre bent tubes and the ease of fabrication time. Crossovers made from PVC are priced according to make and model of engine, amount of bends required, complexity and what is needed for support and heat muffs.

Standard Crossover Systems for 4 cylinder Lycoming

The base system is $625.00
The detachable tailpipes are $75.00 each x 2 = $150.00
8” shroud with 2” ports - $95.00 each = $95.00
Carb heat shroud-$75.00 each = $75.00
Support clamp for tailpipe = $20.00 each x 2 = $40.00

For the whole system with you supplying the final mounting from the clamp is: $985.00

Crossover System w/mufflers

The base system is ...............................$625.00
Mufflers - $195.00 each x 2 = ...............$390.00
Tailpipes - $85.00 each x 2 = ................$170.00
Shrouds - $85.00 each x 2 = .................$170.00

Muffler Pin clamp for tailpipe to muffler w/ support block- $35.00 each x 2 = $70.00

All hardware (nuts, bolts, etc) - ...............$15.00
Blow proof gaskets - $5.85 each x 4 = ....$23.40

For the whole system: $1463.00

Custom Exhaust Systems-
PVC mock up kits | 4 into 1 | 3 into 1 | Single side stacks | Crossovers | Customer supplied samples

We combine our experience with unparalleled service to find solutions for your exhaust needs.

From the most complex exhaust systems to the simplest exhaust repairs, the professionals at Aircraft Exhaust Inc. look forward to working together with you on your next aircraft exhaust project!