Bolt on Horsepower. Complete replacement for your Diamond Star's exhaust system:

FAA approved by STC and for DA40 with Lycoming IO-360 engines, MT propellers and compatible Hartzell Propellers (see below).

Interesting Fact: When Diamond’s engineers saw the performance gains we were advertising when we first introduced our system for the DA40 in 2006, they were convinced that we had to be wildly inflating those gains. They jumped at our offer to let them do their own testing of our system on a DA40 at their facility in London, Ontario. 

The results of those tests (which demonstrated performance improvements even higher than we were claiming) led Diamond to include the Power Flow System as standard, OEM equipment on all DA40-XL & XLS models since the 2007 model year!

For DA40’s that were not equipped with our system at the factory, we offer a complete replacement of your current exhaust system. Our system is FAA approved by STC for DA40’s with I/O-360 engines, MT propellers and compatible Hartzell Propellers.

The same exhaust system that is now standard on all Diamond DA40-XL/XLS series, is available for all MT propeller equipped DA40's.  It is also approved for installation on DA40's that have been upgraded with Hartzell's 2-blade, 7497 aluminum prop or composite propeller installed under STC SA02476CH-D. 

2004-2008 DA40s currently equipped with the 7495S propeller must change propellers in order to install the PFS exhaust. Power Flow is an authorized distributor for this propeller and can include a current price quote from Hartzell with the quote for your new Tuned Exhaust along with a package discount for buying both from us.

The Power Flow System immediately gives your DA40 the following improvements:

• 5 - 8 knots faster cruise speeds

• 10% – 15% increase in rate of climb

• 0.5 – 1.5 gph reduction in fuel burn at equivalent airspeed

• Improved Take-Off Performance (100’ – 300’ reduction in ground roll)

• Increase in Service Ceiling of 2,000’ – 5,000’ with a corresponding improvement in safety margins during high density altitude operations

• Cooler cylinder head temperatures (CHT) in cruise at same speeds

• Cooler oil temperatures during climb - save fuel

• New & improved design for Cabin heat exchanger

• Kit includes a complete 321 stainless steel exhaust system, i.e... 4 headers, cabin heat shroud, carburetor heat, extractor system, muffler, STC, instructions, and all necessary hardware for installation (nuts, No-blo gaskets, etc.)

• Fully FAA STC'd tuned exhaust system manufactured under an FAA/PMA

Our system is a significant improvement over the stock Diamond DA40 exhaust. It is a versatile, quality constructed, complete replacement of your entire exhaust system. You are in control. For more speed, use the extra power. For fuel savings, throttle back and fly your pre Power Flow airspeeds. For improved safety, the entire system is constructed from stainless steel and includes minimal structural welds in the cabin heat section. 

The exhaust system easily installs in less than a day. Your original exhaust outlet in the cowling must be patched (requires additional time). The system can be installed by one of our dealers, by your local A&P, or you can fly your plane to us for a local install. Fly in with a standard Diamond DA40, fly out tuned for maximum performance similar to the XL. 

Our industry leading 60-day money back guarantee means that if for some reason the performance benefits listed above fail to materialize on your DA40, you can return the system to us within 60 days of its installation for a full refund of your purchase price.

For Lead Limes and Discounts see the table below

*   Exhaust Kits have a variable lead time, dependent upon our Sales offer and manufacturing capacity - Please refer to the chart below for current lead times and available discounts.  If you need an exhaust immediately, please call or indicate AOG in the “Notes” section of the online order.  Your credit card will not be charged until the order and shipping cost are verified by our Sales Department and confirmed with you.

**   Prices are for US and Canadian registered aircraft only. International customers may place an order online and will be contacted by Power Flow Systems, Inc. or a local authorized reseller regarding final pricing.

Polished Finish or Ceramic Coated Tailpipe?

The Ceramic Coated tailpipe is a cosmetic enhancement that hides the heat induced discoloration that is characteristic of stainless steel (think of the "bluing" you see on the muffler of a motorcycle). 

This discoloration has absolutely no effect on performance or reliability but the ceramic coating covers it up permanently. Otherwise, the polished tailpipe begins to discolor after a few hours of flying time.

It can be re-polished anytime, but if you are proud of your Diamond’s appearance and would rather spend your time flying than polishing, the ceramic is a nice feature to have.

A couple of other important pieces of information:

#1)  We strongly recommend that the aircraft's propeller be dynamically balanced to within 0.2 ips (inches per second) upon installation of the Power Flow System and every two to four years thereafter. If the propeller is dynamically balanced within 25 flight hours of the installation of the Power Flow System and you furnish PFS with copies of the logbook entries confirming this, PFS will extend the warranty on the Tuned Exhaust System from 12 months to 24 months or 500 Flight Hours (whichever occurs first). 

Doing so every 2 - 4 years thereafter will dramatically improve the useful life and the reliability of every component that is bolted to the engine, including the Power Flow System.

#2)  The Power Flow System has no service life limit. It is designed and built to last several thousand flight hours and will quite likely be the last exhaust system you need to buy for your aircraft.  As with any high performance system however, it must be maintained properly.  Every 500 flight hours or annually (whichever comes first) the four slip joints on the system must be cleaned and lubricated with high temperature anti-seize compound. 

Most Customers have this maintenance performed during the aircraft's annual inspection which adds about 2 hours of labor to the inspection. We have had several of our Tuned Exhaust Systems rack up over 4,000 flight hours of trouble free performance (7,000+ flight hours is the current record in a commercial operation) as long as this maintenance is performed as required. 

Contact us about our Hartzell propeller pricing!

Still not sure if a Power Flow is right for you and your airplane? For complete peace of mind, check out our: 

Warranty & Guarantee

Who wants to gamble with their hard-earned dollars?  You don’t want to and Power Flow doesn’t want you to, either.  That’s why we offer three layers of protection with each system we ship:

• Product Warranty:   Every system comes with a 12 month / 500 Flight hour warranty, whichever occurs first.  If the aircraft's propeller is dynamically balanced within 25 flight hours of the Power Flow installation (before or after) and you furnish PFS with copies of the logbook entries confirming this, PFS will extend the warranty on the Tuned Exhaust System from 12 months to 24 months or 500 flight Hours (whichever occurs first).

• 100% customer satisfaction guarantee:  If within 60 days from the date of the first flight after installation you are dissatisfied for any reason, you can return the system to Power Flow Systems and you will be entitled to a full refund of the purchase price of the system (exclusive of shipping charges and labor) once the system has been received and inspected by Power Flow Systems. Inspection will take place within five (5) days from the return of the system, and an adjustment to the refund amount will be made for any parts missing or damaged. If the original payment was made on a credit card, it will be refunded to the same credit card.  If payment was made by check, a company check will be issued. 

• And, finally, in cooperation with our network of Preferred Dealers, we are pleased to offer our: 

Power Flow's Risk Free Guarantee:

We know that it works, more than 7,300 Satisfied Customers worldwide know that it works, and your local Power Flow Preferred Dealer knows that it works . . .

But, what happens if it doesn’t work on YOUR airplane?

As the name implies, this program lets you buy a Power Flow Tuned Exhaust System for your airplane through one of our Preferred Dealers, have them install it for you, and go fly with it for 60 days, absolutely risk free!   

If it works like we know it will, Great!  Welcome to the world of higher performance!

If the system doesn’t live up to YOUR expectations, or even if it does but you just don’t like all that extra horsepower, simply fly your airplane back to the Preferred Dealer (who originally installed your Power Flow).  That Dealer will:

• Remove the Power Flow System from your aircraft,

• Reinstall your original exhaust (as long as it was airworthy when removed) at No Charge,

• Refund the purchase price and installation charges you paid to have the system installed, & 

• Return the system to us at the Dealer's expense.

Power Flow will even refund your outbound shipping charges meaning that the only thing you stand to lose is your skepticism!

Don't just take our word for it - listen to what some of our customers have to say about the Power Flow tuned exhaust system on their aircraft: