Diamond DA40 Aircraft Exhaust Power Flow Systems

Please email [email protected] for pricing on Power Flow products. Prices fluctuate too frequently to remain current. Include registration number and engine make and model.

Bolt-On Horsepower. Complete replacement of your exhaust system. FAA approved by STC and now available for all MT-propeller-equipped Diamond DA40s, as well as aircraft using the Hartzell 2-blade aluminum (7497) or composite prop installed under STC SA02476CH-D.

Note: 2004–2008 DA40s with the 7495s prop must upgrade their propeller before installing the Power Flow system. Power Flow is an authorized distributor.

This is the same tuned exhaust system installed as standard equipment on all DA40-XL/XLS models—and the key reason those aircraft gained up to eight extra knots. By more effectively clearing exhaust gases from each cylinder, your DA40 receives immediate improvements across the board:

• Faster climb performance
• Higher cruise speeds
• Increased service ceiling
• Cooler CHTs and improved engine efficiency
• The option to fly faster or throttle back for meaningful fuel savings

Constructed entirely from 321 stainless steel with minimal structural welds in the cabin heat section, the system is a durable, high-performance, complete replacement for your stock exhaust.

Installation is straightforward and typically completed in under a day. Your original cowl outlet must be patched (additional time required). Installation may be performed by a Power Flow dealer, your local A&P, or at our facility—fly in with a standard DA40, fly out tuned like an XL.

Performance Improvements:

• Up to 7 knots faster at 2,500 ft
• Up to 15% increase in climb rate
• Up to 1.2 GPH fuel savings at the same cruise speeds
• Cooler oil temps during climb
• Cooler CHTs in cruise
• Improved overall engine efficiency

Exhaust Features:

• Fully FAA-STC’d tuned exhaust manufactured under FAA/PMA
• Complete 321 stainless system: 4 headers, extractor system, muffler, cabin heat shroud, carb heat, STC paperwork, instructions, and all required hardware (nuts, No-Blo gaskets, etc.)
• Improved cabin heat exchanger design
• Typical install time: ~5 hours, plus time for the required cowl patch

Visit Blue Skies Aviation, a PowerFlow Systems Risk Free Guarantee Installation Center.
Download the Installation Manual