OK,
For those that do not know, I flew my new EF 85" Extra on a DA50 with an ES50 Pipe for about 8 flights. Power to weight was awesome!

On last flight the motor mysteriously went back to idle and would not spool up. After an incredible amount of time I finally disconnected the muffler to discover the problem was solved.

This was a BRAND NEW ES50 pipe mind new. I tried maybe a dozen times to call Ed. He simply does not answer the phone. So today I carefully cut the back off of the pipe to see what I could. There was a baffle close to the back that was strong and perfectly in place so I cut that out too. After that there were two more baffles inside. Both were close to paper thin in construction, and both had come loose from the sides and moved backwards.

I may be able to put this thing back together IF I can discover what the proper position of the baffles should be.

Anyone have any ideas?

I now see how to put everything back together. But I need a glue that will withstand the temperature. Any ideas there? How hot will the back end of this pipe get ?

Some of the Hysol epoxys are rated up to 450 degrees

I don't believe in any "glues" that would be trusted here. If the company that built it couldn't make it work I doubt any off the shelf stuff will he better. Spot welding? Aluminum solder? Or am I in left field and these may be CF?? If CF, 450° may be decent but borderline if the engine is pushed or lean at any time. Is there any way to put rivets through the pipe/baffle and use glue as a backup/sealer?

If you have a welding shop in your area it may be better in the long run to get it welded if its metal.

It's a carbon fiber pipe,no welding here.Like already mention go with the Hysol epoxy and maybe some carbon fiber for added strength.

Once contaminated with oil, it would be difficult to get any high temp epoxy to adhere properly, even with the surface well cleaned and sanded. I think you probably have a throw away item there. Is there any warranty?

No warranty. I bought it second hand. The guy that sold it to me had a bunch of them from his place of work that had never been used, so they were as new. But I am now certain these were from the very first batch that Ed made. He had trouble with the glue the first go round and fixed it later. I find it very hard to believe that the guy that sold it to me did not know that.

At this point I am going to at least attempt a repair. It's prolly all for naught, but worth a chance when you consider I like to tinker. We'll see.

So you guys like hyssop better than JB Weld?

What about High Temp JB Weld (Up to 2,400*) ?

Before you throw away if cannot glue in the baffling leave them out. I am sure it will be quite enough.

It's worth a try sense you already have it apart.It will work IF you can get it clean enough for the epoxy or JB weld to adhere to the carbon.I like the idea of epoxy sense you can mix it with carbon fiber and can get more surface area to adhere to with it.I like JB weld because of the higher temp rating and use it all the time.Never tried anything like this so can't say what's best.

My ES 55g fell apart the same way.

I got in touch with Ed and was told that Im out of luck, and that all I can do is throw it in the trash and buy new.

Originally Posted by mk1_turbo

My ES 55g fell apart the same way.

I got in touch with Ed and was told that Im out of luck, and that all I can do is throw it in the trash and buy new.

What year was yours built?

So I ended up gluing it all back together using JB Weld. So far it has worked well. Maybe a dozen flights?

Unfortunately, I did not take the precaution of strengthening the stinger joint (it had never failed). Wish I had, because today I lost the stinger.

Anybody out there have an old ES Composites pipe that is trash? I sure could use the stinger!

So did you gain all your rpm back after repairs.

Originally Posted by closetguy

So did you gain all your rpm back after repairs.

I did not measure RPMs before or after. But the motor sounds the same and the plane flies the same, so I would say 'yes'.