Nothing very exciting about wrapping the manifold - done it many times on all sorts of engines. The video is not bad but here are a few extra tips to make an easier and better job.

I soaked the rolls in hot water for 20 minutes. It was threatening to snow on the evening I chose to do this job and the workshop was very cold -  I’m no hero!!

The single most useful aid for this job is a willing assistant. My partner, Sue deftly handled the unwinding and threading of the roll around the tubes leaving me with both hands free to accurately wrap, overlap and pull the tape tight. (Oh, and take the pictures)

When wrapping around the bends don’t try to maintain a consistent overlap. Reduce the overlap on the inside as you enter the bends and maintain the 1/2 inch overlap on the outside. As the tube straightens again, gradually revert back to an even 1/2 inch overlap all round.

I managed to complete the whole wrapping job with only two cut ends of the tape exposed. I folded the ends under and secured them with ties. I couldn’t find the RW supplied ties but they looked a little naff in the video so I used the ones we supply with our exhaust wrap - Much nicer.

I had to get written permission to bring it indoors to dry out on the boiler. Elvis thinks it’s a good job. Thang you very much.

I painted the wrap with aluminium colour VHT aerosol. Fitting it was rather more of a challenge. Not only were the flange bolts very tight in the Helicoiled threads, the flange positions were quite a way out of line. I ground away most of the meat from a ring spanner until it was thin enough to fit over the bolt heads and I pulled the last couple of flanges in line with a ratchet strap around the engine. I lubricated the threads with anti-sieze and wound them in and out a couple of times. With hindsight, I should have done this before fitting the exhaust.

SILENCER

This is the standard Rotorway muffler which has next to no silencing effect.

I am currently working with UK agents Southern Helicopters on a new silencer design that will be certified for UK use. Preliminary tests are encouraging.

Watch this space.

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