DIY - Replacing stall warning horn (G1000 DA40)

[Chris B]

So, my question - for those of you who have done this replacement before: what is it made of? I would appear that it's only purpose is to block the horn from any incoming air pressure, but then lift out of the way under enough suction to allow the kazoo to play. Any ideas where one would find a replacement for this little check ball?

Hi Rick -

As noted above, the ball is white nylon, and the purpose is exactly what you describe. It is quite light, and sized to easily fit in the vinyl tubing.

In terms of where to get one, you might check with Diamond. Presumably you would not incur hazmat shipping.

Chris

[Steve]

It would appear that it's only purpose is to block the horn from any incoming air pressure, but then lift out of the way under enough suction to allow the kazoo to play...

Actually, the ball is an "anti-insect" device, to keep bugs out of the reed. As noted, the safety pin is to retain the ball.

Steve

[rwtucker]

Ahhh . . . aviation technology.

[Chris B]

Actually, the ball is an "anti-insect" device, to keep bugs out of the reed. As noted, the safety pin is to retain the ball.

I'll take your word for it, but it would seem that the biggest threat for insect invasion would be critters setting up shop in the tubing between the leading edge and the horn. Obviously the ball doesn't help with that at all.

Chris

[Rick]

But . . . where is the ball!

Apparently I've been flying for several years now without one, since AFAIK the stall horn has never been removed or disconnected since I've had the plane. So, I can confirm that the stall warning works just fine without the ball!

As noted above, the ball is white nylon, and the purpose is exactly what you describe. It is quite light, and sized to easily fit in the vinyl tubing.

In terms of where to get one, you might check with Diamond. Presumably you would not incur hazmat shipping.

Maybe no hazmat shipping, but knowing Diamond, it probably must ship in a large steel box to avoid crushing the fragile plastic ball!

Thanks, guys! I may give Diamond a call and see what they say. Or maybe I'll just continue on without it and see if my left knee ever gets wet...

[rwtucker]

Something close to this size?
https://www.amazon.com/Nylon-Ball-32-Di ... 5485578011

[Rick]

Something close to this size? https://www.amazon.com/Nylon-Ball-32-Di ... 5485578011

Hmmmmm... good idea! Now I see many sources for "little nylon balls" of varying diameters "typically used in check valves" (here, for example). I wonder what the correct diameter is? Bigger than the top of the horn, but smaller than the ID of the line, I suppose...

[Rick]

Ok, for future reference - Diamond says the part number is PTFE8 and it's 8mm diameter. It looks like the cost is around $20 from Diamond.

[mdieter]

Ok, so the stall horn in our 2009 DA40 stopped working. Thanks for the excellent tutorial on replacement!

I can't find the referenced part (Cessna P/N 0713348-1) but I see some references to a newer version PN 0513602-1. Anybody have info on this? Do you need a specific horn based on stall speed, or are they all 'calibrated' ;-) the same?

I see the new part available for $81. I know airplane dollars, but if anyone has a less expensive source, please. It's just a kazoo!!

[Rick]

I just looked at my order - I bought the part number you referenced (05131602-1) from AircraftSpruce (Spruce part number is 06-00233). It was $45 last year when I ordered mine.