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Sutton Exhaust Installation and PIREP

Steve Pierce

BENEFACTOR
Graham, TX
I blew out my HD Atlee muffler recently and broke an exhaust pipe last summer at Johnson Creek. I decided to replace the entire exhaust system with the Sutton system. Harder to remove the old system than to install the new one in my opinion since you have to swing the engine and twist and pry the pipes out of the muffler. Removed all of the cowling including the lower cowl rails. I cut the tail pipe off on my chop saw to get a square cut and took the remaining section of pipe to my friend down the road with a muffler shop and had him swedged it until it fit over the tail pipe snug. I don't know haw people get the lower cowl on with a one piece tail pipe. I got the pin clamp from Suttons. They sell the two piece tail pipe system with either a straight pipe or curved. I bought my system unused from a friend so I didn't have that option. It does have the heat ribbons which will probably be overkill in Texas.

I assembled the system loosely and then installed on the engine and tightened up the clamps. There is an air pickup on the front of the muffler so I used my 1 7/8" Greeley punch and installed the pickup provided with the system in my front baffle.
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I have an old lower cowl skin with a large hole where the tailpipe goes. Once the system is installed and torqued I install this lower skin and use tape to mark around my tail pipe hole, drill and rotary file to size.
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I had to remove the inlet scoop on the bottom of the cowl that fed fresh air into the front pipe shroud and patched the hole. I did have to grind some of the right lower cowl rail edge to keep from rubbing the #1 exhaust pipe into the muffler.
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I took some 2" OD aluminum tubing and had my friend with the muffler shop swedged two ends to fit over the carb heat and cabin heat pipes and fabricated and welded 90 degree elbows to eliminate the excess SCAT hose making the corners.
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I lost two pounds by replacing the stock system and the Atee HD muffler. I didn't see any change in static rpm or take off power in the day and a half I have flown it since the change. Like the freed up firewall for sure from a mechanics stand point and heat this summer.

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I made the top of the air scoop in lower cowl removable to allow lower cowl installation with long muffler.... you still had to hold your tung just right and find the right words, to make it go on and off.....
 
I know several people with Sutton exhausts, much cleaner & simpler and more "elegant" than the stock exhaust with pipes running around all over the place.
My C150/150TD had an exhaust configured very similarly.
I like your welded aluminum elbows, much cleaner than a large radius bend using scat.

Trivia question: is your knockout punch a "Greely" or a "Greenlee"?
 
I did one on a Super Cub a decade ago. As I recall, it was trouble-free. Did not notice any performance gain, but the 50 hour muffler check is gone. Well, was gone. Cub Crafters put back the stock system when they changed it to a 180 hp.

I have a similar system on my Decathlon. Bulletproof.
 
I know several people with Sutton exhausts, much cleaner & simpler and more "elegant" than the stock exhaust with pipes running around all over the place.
My C150/150TD had an exhaust configured very similarly.
I like your welded aluminum elbows, much cleaner than a large radius bend using scat.

Trivia question: is your knockout punch a "Greely" or a "Greenlee"?
Greenlee LOL
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Sent from my [device_name] using SuperCub.Org mobile app
 

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Figured it was a Greenlee.
I'm not an electrician but their gear is good stuff from what I've seen.
FWIW "Greely" or "Greenleaf" would be a good brand name for a cheapie knockoff--
kinda like a Rolax watch.
 
Any tips on how not to split the 2" OD AL tubing when swedging it to fit the 2" ID?
 
Just saw this thread pop up and thought I'd add my installation experience.

Quality product and everything bolted up great, until it was time for the lower cowling.

Like you said, I don't know why they leave the stack so long, unless someone has a large removable section I don't know how you'd ever install the cowl.

I ended up cutting the stack down quite short and drilling it for the provided curved tip. (Not pictured)

The lower cowling itself took a lot of trial and error cutting and grinding to make a good fit. Even now, it's a major pain removing and replacing the cowl.

Overall thoughts? I love this exhaust! The heat alone was worth it. Clears up the space behind the engine amd sounds great. signal-2022-04-11-10-13-31-544-5.jpegsignal-2022-04-11-10-13-31-544-4.jpegsignal-2022-04-11-10-13-31-544-3.jpegsignal-2022-04-11-10-13-31-544-2.jpegsignal-2022-04-11-10-13-31-544-1.jpegsignal-2022-04-11-10-13-31-544.jpeg

Sent from my SM-S908U1 using SuperCub.Org mobile app
 

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Had some 2" OD .048 2OD048W6061.jpg6061 laying around and tried to swedge it with not much success. Looks to break on a seam. What AL tubing did you use? Talking the 90deg elbows.
 

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had some 2" od .048 View attachment 608156061 laying around and tried to swedge it with not much success. Looks to break on a seam. What al tubing did you use? Talking the 90deg elbows.

MY BAD did not read into it enough to see you are trying to make the elbows for the carb heat ect. Good luck
 
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