Plans: 1. Fab the exhaust elbow. Status: 50% complete. After talking with an exhaust business I learned that welding stainless steel would require me to bring the aircraft, engine or parts to their shop. Apparently the equipment is not portable. So I decided to cut the pieces myself out of regular steel and use a slip joint for the stainless muffler. Basically avoiding any need to weld stainless. I created the elbow in several steps. 1. Measure the needed elbow bend radius. 2. Sketch the desired elbow's outline on paper. 3. Find the best cut angle using wood pieces overlaid onto the paper sketch (I tried 25, 25.5, 26 and 26.5 degree cut angles). I settled on 26 degrees as the best fit. 4. Cut and glue a 1.5" black pipe mocked-up as a test assembly. 5. Verify any changes needed in the black pipe mock-up. (I made three separate mock-ups built to slightly different dimensions). 6. Make and test a steel pipe version. 7. Have the steel pipe version welded.
