Tag Archives: Engine Exhaust

100cc Extra 260 KS Canister Install

I have had an issue with my AeroWorks 100cc Extra 260 being very loud.  The 3W 110cc CS engine, on stock exhaust, runs about 120db.  Which is not AMA legal and most flying fields won’t let you fly there; as there are noise restrictions.

With that said, I decided to install KS canisters.  This airplane is designed for installing canisters which makes the installation process easier.

The first step in this process was to work with Gerhard, at Aircraft International, to make sure I was getting the right parts for this airplane and engine.  Gerhard spent quite a bit of time with me and I was able to order and receive everything I needed.  On a side note, I highly recommend working with Aircraft International for all of your 3W needs.  I have always received great service and, when ordering anything, very prompt shipping.

The install went very smooth.  All in all it took me about 10 hours total.  The most significant amount of time was spent encapsulating all of the bays.  I used 1/16″ plywood and blocked the bulkhead behind the canisters and all bays that hold electronics.  This is absolutely necessary so the fuselage doesn’t become pressurized and blow off your covering and to keep your electronics cool.

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I measured and cut plywood to cover the bulkhead behind the canisters.  I then cut a 1/4″ plywood canister mount.  You can see this in the image above.  This made it easy for me to epoxy the canister mounts.

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Once the canister were installed the way I wanted, I created a bolt-on cover so I would have easy access for canister maintenance.

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I used flex-headers so I could get the correct drop and positioning I wanted.

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Lastly, I relocated the throttle servo and modified the canister tunnel cover to give it a clean look.

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Yesterday I took the plane out for a few flights.  I had to make a few minor low and high carb adjustments as the canisters produce more back-pressure then the stock exhaust.

These new KS canisters brought the noise level down to 96db, a very big difference.  The plane sounds great!

Thank you Gerhard, at Aircraft International, for your help with the parts.  And thank you Morris and Phil, at the field, for helping me get this thing dialed in!