Applicability: R22, R22 HP, R22 Mariner, R22 Alpha, R22 Beta. Must have Lycoming O-320-B2C engine and large oil cooler ( p/n: C649-1 or p/n: A649-2).
How can just changing the exhaust give you a tremendous boost in power and efficiency? The answer is simple.
Installing a Power Flow tuned exhaust provides the same performance benefits as upgrading to a Beta II, at a fraction of the cost. It is true bolt-on horsepower for your O-320 powered Robinson R22 Alpha or Beta. You simply remove your old, restrictive, factory exhaust system and bolt-on a Power Flow for instant results you can see, feel, and hear. You then operate your helicopter to the Beta II engine performance limitations. The same technology that has been used in race cars, motorcycles, and over 3700 certified aircraft is now available for your O-320 powered R22 helicopter.
Would you like to cruise up to 8 knots faster at the same manifold pressure? Or how about 200 – 300 foot per minute increase in climb? You can even lower fuel burn by up to 15% at your current airspeed. Unlike the factory exhaust, the Power Flow exhaust system does not require mandatory replacement at 2200 hours. For complete list of benefits, see the benefits tab above.
Our tuned exhaust system is designed to use the exhaust gases from each cylinder to help each other, rather than fighting with each other. The factory exhaust system is a very simply design with two exhaust headers entering a central muffler chamber from each side with no separation of the exhaust pulses. The pulses enter the chamber with no particular path to follow. Some leave through the tailpipe, some stay in the muffler (creating back pressure) and some even go back up the other header pipes causing further back pressure. Our system specifically times each exhaust pulse to create a low pressure (suction) at the cylinder’s exhaust valve when the valve is ready to open. This empties the cylinder more completely allowing for more power to be generated. The exhaust gases then exit the tailpipe without interference from the other cylinders.
Power Flow’s “Beta II in a box” along with all of our products comes with a 60 Day Money Back Guarantee and a 1 Year / 500 Hour Warranty.
This system is delivered to you as a complete replacement of your factory exhaust system from the cylinders on down to the muffler (which is located in our tailpipe). It includes everything needed for installation, including a replacement Manifold Pressure Gage with Beta II limitations marked on it. The exhaust system features all new carburetor heat and cabin heating that uses your existing connections and all necessary exhaust hardware.
Estimated installation time is 2-3 hours.
This product was designed in cooperation with Performance Aviation of New Zealand where it already has CAA approval and ten helicopters are flying with the system. FAA certification testing was completed in June 2010, and received final FAA Approval (STC) July 23, 2010.
For new orders, we have delivery positions available with a 6 week lead time. For deposit and purchasing information, please see the purchasing tab above.
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"During run up, noticed are the installed Beta II manifold pressure limits and MAP limits, which were supplied with the new system. I guess we’re operating as a Beta II! Once 80% is achieved, the governor takes over and RPM’s seem to “jump” to the top of the green. Very unlike the stock 320. Very much like a Beta II would react, as memory would serve."
"This helicopter truly is performing as a Beta II."
"The next flight, a solo, with the new Power Flow System will again provide more support to the “Beta II in a box” claim. Two to almost three inches of mercury less during all phases of flight were noticed! Straight and level flight, solo, the manifold pressure gauge was close to nineteen with the occasional dip towards eighteen inches of mercury. This was never experienced before in this helicopter! This is at 70 KIAS. It’s….well, cool!"
"Overall, the Power Flow System was exactly what I was looking for. Increase safety through increased performance. Modernizing what would be considered aging, performance wise and increasing the aesthetic overall mechanical appearance, which in turn, in my opinion, increases value."
"In my honest opinion, for my particular application, the cost is justified. Additionally, the replacement time is on condition and replacement parts, such as the tailpipe insert, or baffle, are available so that performance can be restored.
Finally, I am in no way affiliated with Power Flow Systems and this impression is purely voluntary. I do give permission to Power Flow Systems to use the information and pictures in a way that is of positive influence to others with R22’s or with Power Flow Systems in general. I believe product delivers what it claims to."
Quotes from Justin Dake, Rotorcraft CFI, after flying a Power Flow equipped R22 Beta, N301BP for 8 hours during Power Flow Systems FAA Certification testing, completed June 1, 2010.
“Now the Beta really performs like the Beta II. There is improvement everywhere, but I saw the biggest improvement in hover and takeoff performance.”
“At max gross, with the stock [Robinson original] exhaust we couldn’t hover within limitations. But, with the Power Flow you can comfortably hover within limitations, even allowing that the maximum manifold pressure is 1 inch lower with the Power Flow.”
“With only myself in the R22 and full fuel tanks, I would see 80 to sometimes 85 knots at maximum continuous power. With the Power Flow, I would easily see 85-90 knots. A solid 5-6 knot gain.”
“I got the same airspeed in level flight for about 1.0 inches lower manifold pressure. This should result in a lower fuel burn at the same speeds.”
“I didn’t really notice a difference in sound in the cockpit.”
Justin Dake, Rotorcraft CFI, Jupiter, FL.
"Since the installation of the exhaust system we have noticed a fuel saving of 5 litres [1.32 gallons] per hour in flight training and cruising at low manifold pressure settings, e.g. 20”. We have found whilst doing cross country flights, we are using around 35 litres [9.25 gallons] per hour,(same as a Beta II) but we are cruising with 22” MP, 80 litres [21.13 gallons] on board and 2 P.O.B [People on Board] at around 90-93kts, which is around 5-8kts faster than our own Beta II. This exhaust puts the R22 Beta up to the R22 Beta II performance without a doubt. And with this exhaust system upgrade we are having the same ‘Hot and High’ performance we are currently having with our R22 Beta II." - D. Lealand - Rotorua, New Zealand
"Fuel consumption has shown a consistent 5 Lt/hr [1.32 Gal/hr] reduction when operating at the same airspeed as standard, that’s a 15% reduction in fuel consumption!" - Matt Bailey, Performance Aviation, NZ.
We saw an average fuel consumption with the standard exhaust fitted of 33 litres [8.72 gallons] per hour, with the Performance exhaust fitted we saw an average fuel consumption of 30 [7.92 gallons] litres per hour, giving a 3 litres [0.8 Gallons] per hour fuel saving.
This trial was done with the guys just continuing normal flight training, therefore the results are a fairly accurate representation of the fuel savings you can expect. I do believe that in practice, we will see better fuel savings than this when the hook is refitted and they get back to sling with it. Phase of flight such as hovering and sling will be the times where we will see the most benefit in fuel consumption savings. A flight test was carried out with the standard exhaust fitted, and the same flight on the same day carried out with the tuned exhaust for comparative purposes and the results are as follows.
Standard Exhaust: Climb out @ 23” MAP and constant speed 60kts gave rate of climb of 700fpm. Tuned Exhaust: Climb out @ 23” MAP and constant speed 60kts gave rate of climb of 900fpm
Standard exhaust: Climb out @ 60kts and rate of climb of 600fpm gave a MAP of 22.5” Tuned exhaust:Climb out @ 60kts and rate of climb of 600fpm gave a MAP of 21”
Standard exhaust: Cruise 1000’ at 60kts gave MAP of 18” Cruise 1000’ at 70kts gave MAP of 19” Cruise 1000’ at 80kts gave MAP of 20.5”
Tuned exhaust: Cruise 1000’ at 60kts gave MAP of 17” Cruise 1000’ at 70kts gave MAP of 18” Cruise 1000’ at 80kts gave MAP of 19” Standard Exhaust: Hover MAP – 21.5” Tuned exhaust: Hover MAP – 20.5” - R. Marr - Paraparaumu Engineer - HELiPRO Aviation Support - NZ
General Magazine Reviews on the Power Flow Tuned Exhaust
“…Power Flow systems offer among the best bang for buck of any mods we’ve reviewed.” – The Aviation Consumer – Feb. 2009
“There’s very little available on the aftermarket these days providing the same return rate on investment.” – The Aviation Consumer – Feb. 2009
“…we are convinced they have a well engineered product and they have made reasonable performance claims.” – Light Plane Maintenance – Sept. 2008
“…the company’s money back guarantee almost makes it a no-brainer to give it a try.” – The Aviation Consumer – Feb. 2009
“I’m not a test pilot but… even I could tell there was a difference. It was that obvious.” Flying Magazine, August 1999 (click to read)
"Although it’s not free, Power Flow has created the closest thing to free horsepower that we’ve seen.” AOPA Pilot, January 2000 (click to read)
“A rate-of-climb increase of about 20 percent is remarkable – not to mention the safety factor increase when leaving high-altitude airports or climbing through cloud layers.” Private Pilot Magazine, December 2000 (click to read)
“…boosts the Lycoming O-320’s output by at least 20HP, while simultaneously reducing fuel flow and lowering CHT’s. Geez, what a deal.” The Aviation Consumer, May 1999
“At the conclusion of the flights, there was no questions that the PFS had improved both climb and cruise performance.” Plane & Pilot, December 2006. (M20 200hp)
“Upon opening the large boxes, I was immediately impressed.” Cessna Owner Magazine, September 2002.
“This is a quantum leap in climb performance.” Cessna Pilots Association Magazine, August 1999
“In the aircraft industry, you see many “mods” claiming incredible changes to performance. It is refreshing to see one that actually lives up to its performance claims.” Cessna Owner Magazine, September 2002. (click here to read)
“The engine gets a more complete fuel burn. The effect in the cockpit is that it will take less throttle to get the same RPM” Aircraft Maintenance Technology Magazine, March 2005 (click here to read)
* Exhaust Kits have a normal lead time of 6-12 weeks, dependent upon our Sales offer. If you need an exhaust immediately, please call or indicate AOG in the “Notes” section of the online order. All other in stock items normally ship within 2 business days of order receipt. Your credit card will not be charged until the order and shipping cost are verified by our Sales Department and confirmed with you.
** Prices are for US and Canadian registered aircraft only. International customers may place an order online and will be contacted by Power Flow Systems, Inc. or a local authorized reseller regarding final pricing.
Power Flow Systems has a 100% customer satisfaction guarantee. If within 60 days from the date of the first flight after installation the customer is dissatisfied for any reason, they can return the system to Power Flow Systems and they will be entitled to a full refund of the purchase price of the system (exclusive of shipping charges and labor) once the system has been received and inspected by Power Flow Systems. Inspection will take place within five (5) days from the return of the system, and an adjustment to the refund amount will be made for any parts missing or damaged. If the original payment was made on a credit card, it will be refunded to the same credit card, if by check, company check will be issued.
The warranties provided by Power Flow Systems, Inc. in this Statement of Limited Warranty apply only to Exhaust Systems you purchase for your use, and not for resale, and not from Exhaust Systems that are acquired through transfer of ownership. Installation and use of the Exhaust System constitutes your agreement with the terms of this warranty. The term “Exhaust System” means a Power Flow Systems, Inc. exhaust system, its upgrades, elements or combination of them. Nothing in this Statement of Limited Warranty affects any statutory rights of consumers that cannot be waived or limited by contract. If you have any questions, please contact Power Flow Systems, Inc.
The Power Flow Systems, Inc. Warranty for Exhaust Systems
Power Flow Systems, Inc. warrants under normal use and service that each exhaust system is 1) free from defects in materials and workmanship and 2) conforms to FAA regulations where applicable. The warranty period for an Exhaust System is a specified, fixed period commencing on the Date of Installation. The date on your log book entry is the Date of Installation unless Power Flow Systems, Inc. or the Reseller informs you otherwise.
If an Exhaust System does not function as warranted during the warranty period, and Power Flow Systems, Inc. or your Reseller are unable to either 1) make it do so or 2) replace it with one that is functionally equivalent, you may return it to your place of purchase and your money will be refunded.
Extent of Warranty
The warranty does not cover the repair or exchange of a Power Flow Systems, Inc. exhaust system resulting from misuse, accident, modification, installation errors, unsuitable physical or operating environment, improper maintenance by you, installation not performed in accordance with our current and approved installation instructions or failure caused by a product for which Power Flow Systems, Inc. is not responsible. Power Flow Systems, Inc. reserves the right to deny any warranty claim.
THIS LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES OR CONDITIONS, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THESE WARRANTIES GIVE YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM JURISDICTION TO JURISDICTION. SOME JURISDICTIONS DO NOT ALLOW THE EXCLUSION OR LIMITATION OF EXPRESS OR IMPLIED WARRANTIES, SO THE ABOVE EXCLUSION OR LIMITATION MAY NOT APPLY TO YOU. IN THAT EVENT, SUCH WARRANTIES ARE LIMITED IN DURATION TO THE WARRANTY PERIOD. NO WARRANTIES APPLY AFTER THAT PERIOD.
Items Not Covered by Warranty
Power Flow Systems, Inc. does not warrant Exhaust Systems where end-users attempt to extract a Power Flow exhaust system from a third-party consumer. End-users, who chose to do this, do so at their own risk.
Power Flow Systems, Inc. Exhaust Systems may or may not fit once removed from the aircraft for which it was originally intended.
Power Flow Systems, Inc. does not warrant any outside labor costs associated with the installation, removal, inspection, repair or other considerations of the Exhaust System.
Any technical or other support provided for a Power Flow Systems, Inc. Exhaust System under warranty, such as assistance via telephone with “how-to” questions and those regarding Exhaust System set-up and installation, will be provided without warranties of any kind. Ultimately, it is the responsibility of the installer, A&P with inspection authority or equivalent, to determine the airworthiness of the installation in accordance with FAA regulations.
If during the warranty period, the Power Flow Systems, Inc. Exhaust System is not in good working order, Power Flow Systems, Inc. will, at its sole discretion, repair or replace it at no additional charge, provided that:
the vibration level of the engine and propeller does not exceed 0.2 IPS at a minimum of 2,000RPM (confirmed by a dynamic balance).
the Power Flow Systems, Inc. Exhaust System is installed on an airworthy engine.
the exhaust is in compliance with our Instructions for Continued Airworthiness Instructions (ICAW).
the Power Flow Systems, Inc. Exhaust System is installed on the designated aircraft it was purchased for.
During the warranty period, if warranty service is required, you may be required to acquire a dynamic balance for further investigation.
To obtain warranty service for an Exhaust System, contact Power Flow Systems, Inc. directly within thirty (30) days of defect discovery. Failure to do so and/or using a third-party for repairs or service will void the warranty. You may be required to present proof of purchase and log book entries. You are also responsible for returning the defective Exhaust System or Exhaust System component to Power Flow Systems, Inc. at your cost. Power Flow Systems, Inc. will not reimburse these shipping costs or any outside labor costs that may be associated with the installation, removal, inspection or repair of the Exhaust System.
Power Flow Systems, Inc. will pay for the outbound shipping expense (UPS ground or other non- expedited freight service) from our facility to the customer, but will not pay for shipments inbound to our facility for warranty repair.
1 Year or 500 Tach Hours whichever comes first.
Power Flow Systems, Inc. parts, Power Flow Systems, Inc. labor and shipping replacement to customer only.
Limitation of Liability
NEITHER Power Flow Systems, Inc. NOR ITS SUPPLIERS SHALL BE LIABLE FOR INCIDENTAL, CONSEQUENTIAL, INDIRECT, SPECIAL, OR PUNITIVE DAMAGES OF ANY KIND, LOSS OF INFORMATION OR DATA, OR OTHER FINANCIAL LOSS ARISING OUT OF OR CONNECTION WITH THE SALE OR USE OF THIS PRODUCT, WHETHER BASED IN CONTRACT, TORT (INCLUDING NEGLIGENCE) OR ANY OTHER THEORY, EVEN IF Power Flow Systems, Inc. HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. Power Flow Systems, Inc. ENTIRE LIABILITY SHALL BE LIMITED TO REPLACEMENT, REPAIR, OR REFUND OF THE PURCHASE PRICE PAID, AT Power Flow Systems, Inc.’s OPTION.