Broken Exhaust Bracket.....

[Star57]

We just started our annual and my AME (A&P) wanted to removed the exhaust to look at the heat exchanger, well when we took it out we found that the bracket that holds the exhaust in place was broken on the sides.
Its abour 30cm long and has two holes for the bolts on the sides, it was broken on both sides, the exhaust is the original from 2005.
Has anyone had this problem
Thanks

[Tim H]

I have had two broken muffler brackets in 575 hours (2005 DA40).

There are several Service Bulletins applicable to the exhaust system. Check your logbooks to see if they have been completed or not. On my 2005, the first 3 were complied with at the factory. MSB40-044/1 was completed by the previous owner at 114 hrs.

MSB40-007/4 - Exhaust System
MSB40-033 - Exhaust System
RSB40-040 - Exhaust System
MSB40-044/1 – Muffler Brace

[Star57]

I have had two broken muffler brackets in 575 hours (2005 DA40).

There are several Service Bulletins applicable to the exhaust system. Check your logbooks to see if they have been completed or not. On my 2005, the first 3 were complied with at the factory. MSB40-044/1 was completed by the previous owner at 114 hrs.

MSB40-007/4 - Exhaust System
MSB40-033 - Exhaust System
RSB40-040 - Exhaust System
MSB40-044/1 – Muffler Brace

We got the people at XU Aviation in London Ontario to send it us, Diamond had it in stock $98.00, for a 25 cent steel bracket that is no designed properlly, welcome to aviation.
Hopefully we should be able to assemble it back.

[Graham]

I just replace mine at the annual in Sept for the same reason.
284hrs TT and 2yrs old.

[Tommy]

Same here. Just replaced the replacement. It's less than a year old. Less than 100 hrs. on it.
Three quarters of the entire weld broke around the perimeter of the insert.
If we had not noticed it, I probably would have lost it on my return flight home.
I'm planning on calling Power Flow to find out what the deal is.

[Steve]

Are you guys talking about a broken muffler bracket or a broken exhaust riser? The latter were quite common before the muffler support MSB came out (I had two risers break at once, and Diamond replaced the entire exhaust system under warranty).

Since the support bracket, reports of exhaust riser fractures are much less frequent. But the brackets break with some frequency (although mine is still intact after more than 300 hours...

Hope I'm not jinxing myself...

Steve

[Graham]

Are you guys talking about a broken muffler bracket or a broken exhaust riser?

I was referring to the exhaust bracket.

[Star57]

Are you guys talking about a broken muffler bracket or a broken exhaust riser?

I was referring to the exhaust bracket.

It's the bracket that is sandwiched between the round shroud that supports the muffler, it's about 10 inches long, I took pictures but haven't been able to post them.

It's insane that Diamond knows that these brackets brake and they won't change the design
Companies that won't enhance their products are destined to fail!
This bracket is not applicable to Power Flow exhaust systems, but it sounds like they have their problems too.

[Tommy]

What I am talking about: The cylindrical bracket, with the 90 degree bend, with the four screw holes, that slides into the outer shell, that supports the perforated metal, that is surrounded with what I think is sound deadening insulation that last for only about a hundred hours before it is almost all gone.
It is the metal around the smaller hole of the bracket where the exhaust actually exits that was fractured to the point of losing it within a few hours.
I will try to get pictures.

[Tim H]

I have had the brackets, the risers and even the "flame arrestor" inside the muffler fail (break loose). My IA told me that if the flame arresetor had blocked the exhaust pipe the engine would have stopped running.