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Power Flow Exhaust Systems

Of Course You Love your Cardinal, but
have you ever wanted your Cardinal to...

Take off a little quicker?
Climb a little faster?
Burn a little less fuel?
Arrive a little sooner?

If so, your time has come!

The Power Flow Tuned Exhaust System is a bolt-on replacement for your aircraft's 40+ year old Cessna produced exhaust. Its patented design is configured so that the high and low pressure pulses produced by the engine's exhaust cycle are timed (or "tuned") to more completely empty each cylinder of spent exhaust gases, thus allowing a greater volume of "fresh" fuel/air mixture into the cylinder during the next combustion cycle. The result is an improvement of approximately 15 - 18% in engine efficiency and power output, true "bolt-on horsepower."

Here's what you can realistically expect from that extra horsepower:
  • An increase of 30 - 130 rpm in static thrust (with a fixed-pitch prop).
  • Faster cruise by 5 - 7 knots (with a constant speed propeller).
  • A take-off roll that is 100' to 300' shorter.
  • An improvement in the aircraft's rate of climb by 100 - 150 fpm.
  • Reduced fuel burn (.5 - 1.5 gph) at your current cruise speed thanks to less throttle / Manifold pressure required.
  • CHT's that are 10° - 30° cooler across the board.
  • A service ceiling that is 2,000' - 5,000' feet higher With a corresponding improvement in performance at higher density altitude.
The Power Flow system has other advantages as well. It is built of .049 thousandths 321 Grade Stainless Steel (30% thicker than Cessna's original design), rolled to shape (Not pressed) to reduce stress points and annealed after forming for durability and reliability.

The heater system contains minimal internal welds, greatly reducing the risk of exhaust gas leaks into the cabin. The careful engineering of the total system makes it easy to install and easy to maintain.

This leads to greater power for a given fuel flow and higher maximum power.

Our industry leading 60 day money back guarantee means that if for some reason the performance benefits listed above fail to materialize on your Cardinal, you can return the system to us within 60 days of its installation for a full refund of your purchase price.

Our exhaust system is FAA Approved by STC for C177, C177A, C177B and C177RG & F177RG with Lycoming O-320, O-360, I/O-360, & I/O-390 engines. If you have an O-360 conversion on your 1967/68 C177 our STC is approved for the O-360 engine there as well.

Power Flow has been in business since 1999 and a proud supporter of the CFO community since 2000. Our Tuned Exhaust System is now installed and flying on over 5,000 General Aviation aircraft worldwide (including over 700 Cardinals) making it one of the most thoroughly tested and widely accepted performance upgrades available for this classic Cessna design.

There have been dozens of PIREPS about our system appearing on the CFO Digest over the years including the representative examples below:

For the C-177RG:

A PowerFlow exhaust was installed on my RG last week, and I was amazed at the difference it made! Acceleration and climb were dramatically better, and cruise was somewhere between 5 and 7 knots faster. With two full-sized guys aboard as passengers and full fuel it performed like it used to with only me aboard.

I had been worried that the exhaust note would be annoying, but it's actually rather enjoyable - more of a confident snarl during takeoff than a hum. When I bought my RG over two years ago, I accepted that it wasn't as frisky as other Cardinals I had flown because its engine was close to TBO. But the PowerFlow exhaust has rejuvenated it. In fact, I was having so much fun flying it that I spent a lot of money on avgas over the weekend! John Peck / '77 RG / N52044

Wanted to let you guys know that my new powerflow exhaust has been installed on my Cardinal RG and I couldn't be happier. My speed improvement seems to be about 8 kts with slightly higher fuel flows. Matching book speeds, I seem to be able to save about 0.6 GPH. Quite impressive performance. Installation was very straightforward and it fit like a glove. Excellent product! Love this new system! Best bang for the buck ever! Jim Jeans / N8068G / C177RG

For anyone considering Powerflow but undecided. I have had it installed on my RG since late spring and couldn't be happier with it.

I won't say the performance increases will pay back the purchase price in the short term, but the emotional high from having a plane that performs so well on such a small fuel burn is very satisfying. In addition, the ability to carry a full load out of short and/or higher fields on a hot day and the added safety when operating high, heavy or hot makes it worth the investment to me.

I'm not suggesting anyone exceed the operating limits of the plane, just that this mod gives the plane the performance that it should have, and maybe a little more. Consistent 148 to 150 knots true on 10 gallons per hour and up to 154 on 11+.

Best rate climb lightly loaded in excess of 1100 fpm even on the hottest days. Much more on cool days. Full load hot day climbs of 800 to 900 fpm with better in cool weather. Cruise climb sustained at 500 fpm on a hot day to 8000 ft. fully loaded. Quite a bit more if light or cool.

I apologize that these are general numbers rather than actual test results. My intent is only to say that the PowerFlow met and possibly exceeded my expectations. An added plus is that Tyler, Darren and all the other folks at PowerFlow are great. - Bruce Wallen / '76 RG / N7555V

For the C-177, -177A, & 177B

One of the best products, Performance/$ ratio I have ever applied on an aircraft. Nice job guys!

6000' msl take off. Identical aircraft. Mine had a power flow. 800ft higher coming around the pattern at the take off roll end of runway than stock exhaust.

We all hear about the "10% increase in power claims." After modifying automotive engines for years, most of us think this is baloney because anyone who makes a piece of plastic to smooth out your air intake claims it! Well, I bet the PowerFlow exhaust on my aircraft has increased the power at least 10% . . . Where this really hits home is my increased climb capability, living on the front range of the Rocky Mountains. - Mr. Jeff Bursik / N29379 / 1968 C-177 / O-320

We finished the install of the Challenger air filter and the PowerFlow shortstack this morning, and took it around the patch to see...
  • take off distance ~200' shorter (rough estimate comparing to "normal rotation" point at same wind and temp)
  • rate of climb ~150-200 fpm increase at Vy
  • fuel flow ~1.0 -1.2 gph increase at toga power.
We will test at cruise Saturday, but I sure like it already! - Mr. James Aydelott / 1974 / 177B / N34930

This exhaust, along with our 3-blade Hartzell provides us with the climb and useful load we were "spoiled" with in our previous Cherokee, in a much better cabin! I highly recommend the Powerflow Team and their products!!! - Dennis Pelletier / N34242 / '72 177B

"Climb performance has greatly improved. I have obtained 500 ft/min climb at 4,800 density altitude... I have achieved climbs in the 750-1,000 ft per minute." Mike Hendricks / N2867X / '67 177 w/ O-320

"200 rpm higher in static full power run. 200 rpm higher at 1,000 feet AGL full power. After repitching prop from 55 inches to 58 inches, a gain of at least 15 MPH." Yves Hupee (Canadian A&P) - Candiac, Quebec, Canada / C-FWOE / '68 C-177 (O-320)

General Aviation Press Reviews of the Power Flow System:

"...Power Flow systems offer among the best bang for buck of any mods we've reviewed." - The Aviation Consumer - Feb. 2009

"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)

"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)

"...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

Want to know more or place an order? Please visit our web page or call us at 1-386-253-8833 or 1-USPOWERFLOW (1-877-693-7356 for US and Canada)

Power Flow Systems is a proud distributor of Hartzell Propellers for the Cardinal.

In 2017 Hartzell announced that they have developed a new, 2 blade all metal propeller for the C177RG and C177B. We are an authorized distributor for this propeller for Hartzell and have special CFO member discounts plus extra bundle savings for buying the propeller and a new exhaust system from us at the same time.

6 year / 2400 hour warranty

Complete package - includes propeller and new composite spinner assembly available in 3 finishes: Primed, White and Silver Metallic.

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