Hey All,

I have an O-200 in the worst configuration for making power. Stock Cessna exhaust (soon for sale) out of an C-150, old cylinders with reduced timing as to not blow them apart and slick mags. I'm hoping to up the power output with some efficiency gains. I'm starting with my exhaust.

The plan for my exhaust is a 4 into 1 header made of 304 stainless. So far the specs for my system are 1-5/8" OD with a 38" length for maximum torque.

Has anyone built an exhaust for their aircraft?



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Hi Todd,

  • I first flew with a O-200 basically stock with low compression piston and 150 style exhaust.   I bought a Vetterman exhaust system and noticed s boost in power.  My cruise was 85 KIAS and climb anemic.   I used 2600 RPM to cruise at that 85 K and burned 6 gallons per hour.  More upgrades included 9.5 to 1 piston, P-MAG new prop and Zenith cowl.  Cruising at 100 KIAS and burning 5 gallons per hour. 
  • Talking to others it was suggested I put a C-90 cam to improve torque.  When researching pistons one shop suggested porting the cylinders which would give 5 plus HP.  I am not a racer so no need for that much work.


Thanks so much for the response. I’d like to hear more details about your modifications. I’m sure that would benefit others here too. If you don’t mind could you write a post chronicling your steps and outcomes? My aircraft isn’t flying yet and so I don’t have any base numbers to start with.

i will share my header build here as I get parts in and things put together.

ive heard the same about the C-90 cam, but I don’t think it’s the final say in torque in the O-200.

Does Vetterman make a system for the Zenith? I thought they just worked on RV's.

I just got word back from Vetterman, than do make a couple systems for the 0200 installed in a 750

Lonnie, did they quote you a price?  thx

Don, They did but I can't find it but as I remember is was just shy of $1100 for unmuffled and $13xx for muffled. They said it wouldn't be hard to beat the c150 exhaust.

Started my header setup for the O200. I will have carb heat muff between the two white zipties. For those wondering this is an ice engine works header mock up kit. The header will be constructed out of 304 stainless.035” wall tubing. This right side will need two 2” radius bends and two 4” radius bends to complete. Hopefully my daughter will have the time to weld it all up. Ordering the steel next week.

$600+ of 20 gauge 1.5” 304 Stainless Steel tubing

Love the workmanship. Don’t have a clue what I’m going to do w mine yet. And I also know next to nothing about exhaust systems, but are the pipes too close?  Too much heat?  I don’t know. Wish I had your ability to create this system...I’ll likely be paying someone. Well done


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