"What's News?"

11-30-2012

Major Production Interruption at Leading Edge Exhaust System October 2011. Shutdown was caused by a faulty Pines # 2 Mandrel Bender- S.N.11235-97031 Dial a bend programming computer.

In early October 2011 we were doing a 20 set run for our very popular exhaust system that is used on the Super Cub 150,160, 180Hp; PA-12 150, 160 180 Hp for both the long and short mount; KW Aviation PA-20/22 150, 160 and 180Hp models.

The 20 set run is very labor intensive both in constantly having to change out compound tooling and pulling some of the most difficult back to back 1D bends anywhere in the industry, with plane rotation and as little as .034” straight between bends,.

About half way through the bending operation the bender went out of control so the E Stop was hit to hopefully eliminate major tool damage like what happened in 2002.

Pines Service was called immediately and Bob Nosky evaluated the situation over the phone. He advised us to enter several auxiliary codes and said the encoding gear was the problem. Pines parts manager Mike Koleski sent a new encoding gear to get us back on line. The gear was removed and the new one installed. After examining the encoding gear, that was removed, it seemed odd that the gear hub was made of what appeared to be brass, but had plastic gear teeth. The unusual arrangement of plastic gear teeth being meshed between the other 2 solid tooth gears is something I have never seen before. Maybe it’s another proprietary part of Pines’ Technology.

Once the encoding gear was changed Mr. Nosky walked us through more auxiliary codes trying to analyze what else had failed. After programming in many codes he determined it was the mother board and requested we send it back to Pines Technology in Westlake, Ohio. A total of 3 mother boards were sent back simply because the boards still had components plugged in and had no way of testing components in house, so we decided to send all 3 boards back. We requested out of the 3, build one that could get us back on line so we could complete the bending and start assembling the many sets on backlog.

The good mother board that was sent back to us was installed. Mr. Nosky was contacted for aux code system checks. Again it was a futile attempt and now the problem was supposed to be the independent clamp die and pressure die board along with the 40 pin ribbon cable that suffered damage; after I was instructed to disconnect it from the mother board and install a chip in its place no lees than 3 times. Long story short, the cable needed replacing. Mr. Nosky said they did not have the cable. He said he was going to contact the cable broker’s they use to locate one. We Googled all the major ribbon cable manufacturers and struck out. The cable we were seeking was a 40 pin ribbon cable. The ribbon cable suppliers we called said their cables had female ends and the one we were looking for must have been proprietary due to it having 40 male pins, much smaller diameter than a sewing needle and not nearly as rigid. No one could help.

I Dane Wagner, Owner, Leading Edge Exhaust Systems arrived at Pines on October 4, 2011 to check on the status of the independent CD/PD board and the 40 pin ribbon cable. I requested the board and cable be sent back to Alaska on the week of the November 7th. Mr. Nosky said at the time he was having a spare 40 pin ribbon cable made. The parts arrived around the mid to latter part of the week only to discover the 40 pin ribbon cable that connects the independent CD/PD board to the mother board was about 6" too short. I asked the following question multiple times that can be corroborated in my emails; why would Mr. Nosky want to have a back up 40 pin ribbon cable made when the one he sent was about 6" too short in the first place? I was never provided an answer.

Many calls later, after much frustration and dealing with the onslaught of customer inquiries requesting a completion date for their order, Jeff Smith, senior field service technician, contacted me and I started feeling much more confident the problem (s) would be finally resolved. Jeff presented me with a very in-depth list of system checks to complete. After spending many hours trying to accomplish the task at hand, I emailed Jeff and said I was done. I performed all of his requests and never received a response from him.

I have a very diverse back ground but being a Pines’ tech was not in the cards. My forte is designing and fabricating high performance, US patented, FAA/PMA approved general aviation exhaust systems. I liken the Pines’ process of elimination to the following example; a car wouldn’t start so the mechanic removed and replaced the fuel filter, fuel pump but the car still wouldn’t run and next process of elimination was to replace the carburetor and nothing changed. The mechanic and extremely frustrated customer walked around behind the car to physically push it out of the way and the noticed a big puddle of gas on the ground.... after all that, the problem was a hole in the gas tank and what compounded the issue was the car was just not a car, it just so happened to be a taxi cab the car owner’s way of making a living...just like the bender is my way of making a living…. so much for the process of elimination theory! The hole in my gas tank ended up being Pines’ Technology Dial a Bend processor. Having said that, I must say in all honesty, the Pines #2 Mandrel Bender in and of itself, is a very reliable work horse.

I will close by giving a little advice to prospective mandrel bending customers; make sure and ask the manufacturer how long will they stock critical component parts? Are the components proprietary? My unit is only about 14 years old and was told initially that the ribbon cable was not being produced any more but then that statement was contradicted by Mr. Nosky when he said he was having a spare 40 pin ribbon cable being made, something I never saw. I also said I can still get parts for a model A Ford. I realize it is in the after market but a company with literally thousands of mandrel benders being used around the world Pines should provide their customer’s with a list of approved after market parts suppliers; if in fact they do not produce the component part any longer. The prospective customer should be made aware of this at the time of sale and/or before the manufacturer decides to take it out of production.

Here it is December, 2 months, and I’m still out of production!

I decided to publish this for all the frustrated customers who have exhaust systems on order. I am doing everything possible to get back into production and felt it necessary to give all of you a heads up.

Latest 12-7-11 update, I have contracted with Horn Machine Tools to come to Alaska in January to install their touch screen interface processor. I called 3 very well known mandrel bender service/rebuilding companies and they told me the first thing they do is yank Pines’ Dial a Bend processor and throw it the trash and I’m doing the same thing. Pines provided me a bid on installing a new computer/processor that prompted me to ask the question; are the components proprietary? Their reply was, that’s a good question. I never heard back from them. I hope to be back in production in January and will get the many systems on back order built and out the door. Regarding the Piper exhaust systems I will be building the muffler, muffler shrouds, CAHF’s and the ancillary components so when I get back up and running I can finish the bending and get your orders finally on the way to you. I can assemble a set of pipes in about a day but that does not include the 4 hours of polishing time. I very sincerely apologize for the delay but it was out of my control. Horn Machine Tools said they will get my bender back on line and the nice thing is they do not use proprietary components, meaning the controls are available at electrical supply outlets.

Thank you for being so patient during these very trying times. Sincerely, Dane Wagner, Owner, Leading Edge Exhaust Systems, LLC

5-01-2009

Attention Cessna 180, 182 and 185 owners. Check out the US Patented "Power Monster Cross-Flow" dual exhaust system offer below.

Be one of the first to get a Leading Edge Exhaust Systems' high performance dual exhaust system!!

Please provide the following information to have your name added to the Cross Flow Dual Exhaust “Build List”. You will be assigned a priority number and future contact with you will be made by the priority number assigned. The “Build List” priority is for the first 200 systems only. Subsequent orders will be filled on a first come/first serve basis. Once we obtain the STC you will be contacted and have one week to make the 40% down payment. If we do not receive payment within 1 week your name will roll to the bottom of the list. Please remember this is a 30,000 aircraft market. LEES has already received a lot of inquiries and interest will grow exponentially once STC approval is granted. There is no guarantee on completion date if your name is not on the”Build List” so…… we suggest you sign up now!!

Those of you in the “Experimental Crowd” please submit the same information and your name will be added to the”Build List” in the priority we receive your data. We are currently in the process of tooling up and will build the Experimental Customer’s systems while we are conducting noise and flight testing for the STC customers.

The anticipated normal retail price is $4995.00. The down payment required will be $1998.00 with the balance due upon completion.
Information required: your name, address, phone number, email address, aircraft model number, aircraft model year, model engine, horsepower, what propeller and are you on floats, wheels and/or skis.

Email Address: Performance@wemakeyoufly.com

Please check out the Cessna 180, 182 and 185 " Power Monster Cross-Flow" dual exhaust system product page for photos and all the details!!!

Thank you, Dane Wagner, Owner

6-11-2008

Think Green!! Save on High Fuel Costs!!

Leading Edge Exhaust Systems’ hand built, custom, equal length exhaust collectors reduce back pressure (balanced to .05” psi between all cylinders) and balance the engine operating characteristics so well that a single horsepower is produced with less fuel when comparing LEES’ BSFC, brake specific fuel consumption, to the stock exhaust system, BSFC. Brake Specific Fuel Consumption is the amount of fuel required to produce one horsepower. In all of the dyno pulls using LEES’ pipes the BSFC was much lower when compared to the stock OEM exhaust system.. If the pilot cruises at the same engine rpm level as before the installation of LEES’ “Bad Boy” pipes fuel consumption should be lower. Using LEES’ pipes the engine will be able to produce more RPM’s so it is up to the pilot in command to have enough discipline to keep his foot, or hand in this case, out of the throttle in normal cruise.

Other applications will prove there is more power available. If you stop and think about the definition of a horsepower being the amount of power required to raise 33,000 pounds one foot in one minute, the only way you would notice it is under a load: short field and glassy water take offs; obstacle clearance or heavy gross loads.

My son gave a good analogy when he said it would be like me pulling up next to his pick up, in my Pro Street 600 Hp small bock77 Vega, on the highway and we both are cruising at 55 mph. You would not see or notice any difference between the vehicles until I romped on it. Obviously when I put it under a load the horsepower advantage would be very evident. So having more power has very positive aspects but it requires self discipline in order to realize fuel savings.

10-03-07

Leading Edge Exhaust Systems is in the process of discussing production of the US Patented Cross- Flow dual exhaust system to fit the Cessna 180, 182 and 185 model aircraft with some prospective investors. They have asked us to corroborate the market potential so I’m turning to you, the aircraft owner, to assist us. The pre STC advance purchase discount will be discounted 10%  for the first 100 units.  The advance purchase price will be $4495.50. We offered a similar type  promotion for the Piper Super Cub exhaust in 1999 and 2000 with great success.

Once we receive your data it will be entered it in a computer data base and will be assigned a priority number. It could take several months to acquire data but more than likely will probably be much sooner because the market is so large. Please supply us with the following: Your name, address, phone number, email address, aircraft make and model, engine make and model, floats, wheels and or skis, propeller and engine mount.

We feel confident that the prospective investors will contact some people on the list as part of their due diligence process.

When we get closer to going into full time production we will contact you in the priority order we assigned when we solicited your data.  We will require 40% down or $1798.20 that you will be required to supply within one week. We accept Visa and Master Card credit cards. The balance due will be collected once your system is completed. If you cannot pay the 40% down then your name will be moved to the end of the list.

If you are not one of the first 100 customers we will still apply a priority number to your data and you will be contacted as the systems are completed. You will be contacted by the priority number assigned. 

Please contact your friends or other pilots that would seriously be interested. It has taken too long, as it is, and if we can get the endorsement of this prospective investor group then we can finally get this show on the road.

I cannot give you an accurate production time frame at the present time because the bend and press form tooling will need to be manufactured. The faster we receive the customer supplied data the sooner we can go into production. As history has taught us prices will probably keep increasing so the advance purchase price will save you a substantial amount of money.   

04-01-07

The PA-18-150/160 Hp model exhausts were recently approved to include the new RMW and CAHF as options to the original STC’s.

The Revised Muffler Weldment, RMW, and the new Carburetor Heat Flange, CAHF, are now approved for all models shown on the approved model list, AML. The 180 Hp model is currently undergoing carburetor heat testing and should be approved soon. The RMW muffler has exactly the same high performance internal baffles as the standard issue muffler. Most external flanges welded to the can are needed for carb heat generation have now been removed, substantially decreasing the parallel to the grain fillet welds and increasing life expectancy. It’s not uncommon for our muffler baffles to last over 2000 hours. The RMW muffler can now be used entirely for cabin heat which is a real plus in cold weather. The left side is utilized for main cabin heat and the right side is for rear seat heat. The carburetor heat is now generated in the CAHF. The RMW muffler has a 1000 hour/10 year warranty. If you place and order for a new exhaust system.

The PA-18 150/160 Hp exhaust systems with the Carburetor Heat Flange, CAHF is priced at $3495.00. RMW and CAHF can be ordered separately to upgrade the original exhaust system. Call for current prices.

9-05-06

Leading Edge Exhaust Systems, LLC, LEES, is seeking motivated, experienced, well respected general aviation businesses to become LEES’ domestic and international dealers.  If selected, you can become a distributor for LEES’ popular FAA/PMA approved Piper and Cessna exhaust systems. LEES has many more innovative high performance exhaust systems both in initial and final developmental / testing stages. LEES is also developing exhaust systems for the experimental category. Please provide references when submitting inquiries. We would appreciate you submit queries and references by email to: performance@wemakeyoufly.com.

8-12-06

Leading Edge Exhaust Systems, LLC has developed an Exclusive Website Offers page that will feature monthly discounted sales exclusive only to their website. To review the monthly sales specials just click on the button “Exclusive Website Offers” button located on their home page.

7-20-06

Pre 55 Cessna 180 dual exhaust system. We have expanded the list of aircraft to include more models even though pre-55 has grandfather rights regarding noise testing. No noise testing is required provided the logbooks can document it was flown prior to January 1, 1955. We decided to include several more years simply because there are more model years that the system will fit. We are presently involved in developing the product specific completion program, PSCP. When it is completed and the specific aircraft we need is located, testing will commence. In the meantime, numerous field approval have been granted nation wide. Please look at our Pre STC advanced purchase special. You save $500.00.

5-06

GlasAir Sportsman 2+2 prototype was completed utilizing LEES power proven Super Cub muffler.  Four new risers were developed using our Equal Length theory. The pipes were  sent to LY-CON Engine Rebuilding in Visalia, CA. WWW.LYCON.com, phone number 559-651-1070 where dyno tests were completed. The high performance 180 Hp engine not only produced 15 more Hp but RPM's were increased 200 rpm's. The test was done utilizing the stock no baffled equal length exhaust system and the LEES new 180Hp equal length pipes. No other changes were made except the exhaust system was swapped. All other variables remained exactly the same. We are working with the aircraft owner and mechanic here in Anchorage to install and perform flight tests soon.

5-06

Maule manufacturing and LEES are in the process of collaborating to build a new equal length component dual exhaust similar to our time proven 2000 hour/20 year Cessna 205/210 dual exhaust system. Just as soon as we get an IO540 powered aircraft lined up we will proceed with developing a new system. We will have the system dyno tested once it's completed. We are anticipating designing and building it over the winter months of 2006. We have over 20 years repairing the Maule exhaust in our Repair Station ABC Mechanical Services, FG4R179M, and knows what needs to happen to have a much better performer and very high TBO exhaust system.

4-06

LEES 150Hp equal length Super Cub High performance exhaust system was installed on  Murphy Rebel in Canada. The owner is in the process of getting us some photos to publish. He said rpm's increased both static and in flight. In flight cruise speeds also increased. The exhaust system the owner installed after the plane was completed was the old tandem style Piper PA-12 exhaust system. We knew that the rpm and power would increase based on previous dyno tests at LYCON Engine Rebuilding using LEES High Performance exhaust. If you are building a Rebel and utilize a Piper PA-12 short mount engine mount our pipes will probably fit. I believe you can request an engine mount like our customer built and gain great performance. It’s worth a try!!Our Canadian customer our system fit like a glove and produced great power. We will publish the data and picture as quick as we receive them from Canada.

01/16/06

The Piper PA-12 150/160 Hp short and long engine models passed FAA testing and now are PMA approved for the Aircraft Model numbers PA-12 and PA-12S.

03/16/04

Dyno tests just completed comparing Straight pipes, Stock Super Cub, and Sutton exhaust system. Read the eye opening results...

Now you can make an educated decision based on the Dyno test data supplied.

1st test: LY-CON straight pipes 204HP-396 lb/ft torque @2740 RPM

2^nd test Factory issued OEM Super Cub Exhaust System that includes muffler baffles: 185 Hp-370lb/ft torque @ 2650 RPM

3^rd test Sutton Exhaust 176Hp-356 lb/ft torque @2630 RPM without muffler baffles

            Now it's your turn do some basic math. If you have a stock engine and a stock Super Cub OEM exhaust and know what the factory numbers are; HP; Torque; and RPM you can do your own comparisons. Each individual engine can have different test results. The test results we discuss here were for the model engine listed. The engine test results can vary based on these variables, including temperature, humidity, altitude, mixture and propeller.

We hope this test data will help everyone understand the actual and more importantly realistic performance gains before they spend their money on products with unsupported claims.

12/18/04

The Piper PA-12-150/160 Long mount test plan will be submitted shortly as a plane has been identified to be utilized during the upcoming climb/cooling and carburetor heat tests. The test plan is supposed to cover both the 150/160 "Short mount" and "Long mount" applications.

Leading Edge Exhaust Systems, LLC has sold their famous "Born to Perform" trademark to Jaguar, a division of Ford Motor Company. Leading Edge Exhaust Systems' new trademark and domain name is www.wemakeyoufly.com and their new e-mail address is performance@wemakeyoufly.com

PA-12 -180HP Exhaust System Assembly is now approved and available for sale. LEES is presently taking orders. Call toll free for pricing- 1-888-534-3343. Upcoming tests will be for the PA-12-150HP and 160HP short mounts. The PA-12-150 & 160 HP long mount will follow shortly thereafter.

*Super Performance 6-04-Customer Dyno Test completed at LY-CON Engine Rebuilding. Gain 16Hp and 27lb/ft of torque with Leading Edge Exhaust Systems' P/N PA-18-150ESA and 150HP Lycoming O-320-A2B engine.

*Super Performance 6-04-Customer Dyno Test completed at LY-CON Engine Rebuilding. Gain 13Hp and 22lb/ft of torque with Leading Edge Exhaust Systems' P/N PA-18-160ESA and 160HP Lycoming O-320B2B engine.

*Super Performance 6-04-Customer Dyno Test completed at LY-CON Engine Rebuilding, Gain 22Hp and 20lb/ft of torque with Leading Edge Exhaust Systems' P/N PA-18-180ESA and 180Hp Lycoming O-360-A1A engine.

Dyno Test Results reflects the difference in Hp and torque using the same engine when comparing the OEM (stock) or "other" Super Cub exhaust systems to the Leading Edge Exhaust Systems' part number listed.

Note: Dyno test information is obtained doing static pulls on an aircraft engine dynamometer. The following test was conducted at LY-CON Engine Rebuilding. The results are presented for "professional pilots" and mechanics that assume when baffles are removed from the muffler, the engine will produce more horsepower and torque. The test results will probably surprise you. With no baffles in muffler and the engine leaned to peak rpm the engine lost 2 Hp and 7lb/ft of torque and in the full rich mode the loss was an additional 3 Hp and 3lb/ ft of torque. The total loss was 5Hp and 10lb/ft of torque, full rich, when compared to the same Leading Edge Super Cub Exhaust System PA-18-150ESA with muffler baffles installed and leaned to best rpm.

Attention High Performance Experimental Crowd! Check this out. Using LY-CON's "Bad Boy" 11:1 compression 160 Hp. Exp. engine and Leading Edge Exhaust Systems' P/N PA-18-160ESA together pulled 197 HP and an unbelievable 371.2 lb/ft of torque. That is more torque than the 180Hp engine produced with nearly the same Hp.

LEES just received US Patent # 6,796,402 for the unique muffler design the new Cessna 180,182 & 185 "Cross Flow" dual exhaust system.

LEES new Cessna-180 "Cross Flow" exhaust was recently dyno proven at LY-CON Engine Rebuilding. Gain 13Hp and 28lb/ft of torque over the stock exhaust system on an O470 engine leaned to 2600 rpm using the new Leading Edge Exhaust Systems', LLC "Cross Flow" dual exhaust system. 

The latest Dyno test was done at LY-CON Engine Rebuilding using one of Ken's IO550 Exp. 11:1 compression ratio engines. It pulled 354 Hp and 668 lb/ft of torque with the stock Cessna exhaust system @ 2700rpm's. Using Leading Edge Exhaust Systems' new "Cross Flow" dual exhaust system it pulled 381 Hp and 708 lb/ ft of torque @ 2700rpm's, a 27 Hp gain and 40 lb/ft of torque!

*Dyno tests performed at LY-CON Engine Rebuilding. LY-CON Engine Rebuilding is the largest FAA certified engine rebuilding shop on the United States west coast. LY-CON is a Lycoming / Continental distributor and is FAA certified for Lycoming OEM rebuilding. LY-CON also builds a wide array of high power, high performance experimental engines.

LY-CON Engine Rebuilding is located in Visalia California, Phone number- 1-559-651-1070, Fax number - 1-559-651-3212, e-mail lycon@lycon.com and website www.lycon.com.


12/18/04

Leading Edge Exhaust Systems,LLC is now accepting advance orders for the Pre-55 Cessna 180 aircraft dual exhaust systems. Exhaust Systems will include new US Patented 3-1 exhaust collectors, two new mufflers, shrouds, tailpipes and hardware. Each advance order sale price, $3495 that is $500 less than the anticipated sales price of $3995.00. Each advance order will receive a priority number. The priority number will be printed on the invoice/receipt. The exhaust systems will be built and delivered in the same priority number sequence. Customers are urged to place orders as soon as possible due to the anticipated high demand. Anticipated STC approval time is one year. Leading Edge Exhaust Systems, LLC reserves the right to terminate this offer at their own discretion. After approval for the early model Cessna180's LEES will concentrate their efforts on the newly patented "Cross Flow" dual exhaust system for the later model Cessna 180, 182 and 185's.

LEES is starting the FAA approval process for the Cessna 180, 182 & 185 muffler baffle kits. Kits will be approved for sale and installation by other facilities. LEES separate repair station will also install them for a flat rate. LEES is going to offer, what we feel is, the best warranty in the country. Our Cessna US Patented, FAA/PMA approved 205/210 exhaust collectors offers a 2000 hour or 20 year warranty. Muffler baffle warranty will be 1000 hours or 5 years. Other common muffler baffles usually offer 1 year/unlimited hours.  One of LEES' customers has a set of the new US Patented 185 muffler baffles installed that presently has 2000 hours on them. LEES experience with muffler baffles has shown that the OEM muffler baffles usually last about 300 to 400 hours. To repair the muffler the entire exhaust system has to be removed, muffler gutted, rebuilt and then reinstalled. Downtime and expense is incurred. LEES say their US Patented, FAA/PMA muffler baffle repair kits will be competitively priced and will far outlast other baffles.

LEES plans to have FAA/PMA approved parts available for exhaust system repairs covering all of the most popular and common exhaust parts & fittings. LEES will be the only United States manufacturing company, that their aware of, selling FAA/PMA approved exhaust system repair parts. LEES will update their website periodically so make sure you check it out! www.wemakeyoufly.com.