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Thread: Trial fit of Sutton Exhaust on an O-235 powered Clipper

  1. #1

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    Default Trial fit of Sutton Exhaust on an O-235 powered Clipper

    My Sutton exhaust arrived last night, so out in the shop to do a trial fit today. From discussions with Dawley Exhaust and others, the O-235 is 3/8” narrower at the exhaust flanges than an O-290 or O-320, so I was a little concerned about fit. On the other hand, almost all the STCs to install O-290 and O-320 engines in Clippers, Super Cruisers and Family Cruisers say to use the existing exhaust system.

    Trial fit found that all is good with a slight preload on the exhaust stacks. I’ll likely sand about a .050 taper on the flanges to relieve that preload.




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  2. #2

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    Default Re: Trial fit of Sutton Exhaust on an O-235 powered Clipper




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    Default Re: Trial fit of Sutton Exhaust on an O-235 powered Clipper

    The nice things are it is 6 lbs lighter than the original exhaust, and it gets rid of the exhaust AD inspection. I’ve already gotten a Field Approval for it.

    It requires a light weight starter, so here is the trail fit of the SktTec 122-12XLT installation. Skytech claims 6.5 lbs, but mine is 6.62 lbs. that’s another 9.3 lb savings. Between the starter and the exhaust, that’s a savings of 15.3 lbs!


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  4. #4
    Gilbert Pierce's Avatar
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    Default Re: Trial fit of Sutton Exhaust on an O-235 powered Clipper

    Looks great. So does the snow blower.

  5. #5
    Administrator Steve Pierce's Avatar
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    Default Re: Trial fit of Sutton Exhaust on an O-235 powered Clipper

    I never knew or noticed the difference in the exhaust dimensions between the O-235, O-290 and O-320. Interesting.

  6. #6

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    Default Re: Trial fit of Sutton Exhaust on an O-235 powered Clipper

    Quote Originally Posted by Gilbert Pierce View Post
    Looks great. So does the snow blower.
    Fortunately haven’t had to use it this year . . Yet.


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    Default Re: Trial fit of Sutton Exhaust on an O-235 powered Clipper

    Quote Originally Posted by Steve Pierce View Post
    I never knew or noticed the difference in the exhaust dimensions between the O-235, O-290 and O-320. Interesting.
    I didn’t know either. Dave Sutton and Divco were the ones that pointed it out. Divco said they would put one together for the O-235, but it wouldn’t have the PMA tag on it. I elected to go with the stock one and take the chance it would work. That way, if someone wants to upgrade to an O-320 in the future, they have the correct hardware.


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    Gilbert Pierce's Avatar
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    Default Re: Trial fit of Sutton Exhaust on an O-235 powered Clipper

    I used the exhaust system off my O-235 on my O-320 for 1000 hours before I got fed up with 100 and 50 hour inspections. I had no other exhaust issues. The Sutton decision was a no brained for me.

  9. #9

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    Default Re: Trial fit of Sutton Exhaust on an O-235 powered Clipper

    Quote Originally Posted by Gilbert Pierce View Post
    I used the exhaust system off my O-235 on my O-320 for 1000 hours before I got fed up with 100 and 50 hour inspections. I had no other exhaust issues. The Sutton decision was a no brained for me.
    One of the main reasons I went for it was to eliminate that AD inspection. The 6 pounds lighter is a great plus. Opening up the firewall for mounting a battery and remote oiled filter is icing on the cake!


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  10. #10
    Gilbert Pierce's Avatar
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    Default Re: Trial fit of Sutton Exhaust on an O-235 powered Clipper

    The rear oil cooler, air oil separator and plumbing made getting to the left mag a nightmare. It’s all nice and open now. Hated to cut that hole in my new lower cowl though.

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