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How to build your own Carbon Fiber muffler......

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So.....I`m at it again. I have been wanting to make a Carbon Fiber muffler for a while now.....But it was`nt really till last trip to Moab......That it shifted into a higher priority. I have tried to make a few patch solutions for the powerful MRD/SSW system.......But even being somewhat success full at capping the noise.....I felt I could do better by redesigning the muffler, and complete carbon fiber....rather than a hybrid. Here is a little background of the r/d I have done so far.....

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https://thumpertalk.com/forum/showthread.php?t=730310

I also posted a poll here on TT to gather the thoughts about the shape of the new muffler.....

https://thumpertalk.com/forum/showthread.php?t=764304&highlight=

So with that now behind me I am ready to start on the final chapter. I know I will loose some power...as seen here....

https://thumpertalk.com/forum/showthread.php?t=730310&page=4

By merely putting on my tip on Eddies 60 hp monster....Is fell back about 2.5 hp......Was quite abit quieter though......So this is not a try to find a solution to quiet the system without power loss.......I have come to respect the fact that it is simply not possible.... What is possible though....is to try to minimize the power loss....while maximizing the dampening effect. That`s where it gets interesting. There will first be some r/d, and I thought it would be good to include this as well. First I will need to satisfy a base line....With the open MRD/SSW......

p><p><img src=[/img]

107 DB at sae 4000rpm C weigh`ing and fast response.

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And 3 20 inch long cores to try a single core setup....and a twin core setup...

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The r/d part will be done in sheet metal for ease of construction, and to discover the effectivity of the two systems. Then when I select the final one...I will make the end caps from stainless steel....and of course wrap it in Carbon Fiber.

That said......I will post up as I go along, as this will take some time....But it looked like fun when I did that with the CF integrated tail light......:doh::snore:

Erling

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Hey erling! What would we do with out you? Long live CF!!!!!!cheers Logan

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Your the man Erling. Once again we are in awe of your work and can hardly wait to see and hear the finished product. It is people like you that are the reason we all don't have the same looking bike. :doh:

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Hey erling! What would we do with out you? Long live CF!!!!!!cheers Logan

Thanks Logan...:doh::snore:

Erling

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Your the man Erling. Once again we are in awe of your work and can hardly wait to see and hear the finished product. It is people like you that are the reason we all don't have the same looking bike. :doh:

Individual`ism is a great thing....No matter how one achieve it.......:snore:🤣

Erling

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I am hoping to dedicate tomorrow to make the first test run on muffler one....:doh::snore:

Erling

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One tip. If you are using a room temperature resin (epoxy, polyester, or vinylester) then you should post cure it at an elevated temperature for a few hours just to add some safety. Let it cure at room temperature, then let it sit at about 200-250 degrees F for a couple hours. Room temperature resins do not do well at high temperatures, but if you expose them to elevated temperatures (not so high that is bubbles the resin) then it increases maximum service temperature, strength, and stability of the resin in most cases. For this application I would go with a laminating epoxy resin, as most I have seen have higher maximum service temps than most polyester or vinylester resins. Hopefully heat won't be a problem since the silencer can stays much cooler than other parts of the exhaust.

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You work always blows me away, and I really admire you for doing it...I'm dying to see how this comes out.

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Erling,

If your resin can't handle the heat, I've got an oven and prepreg just laying around that you could use.

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One tip. If you are using a room temperature resin (epoxy, polyester, or vinylester) then you should post cure it at an elevated temperature for a few hours just to add some safety. Let it cure at room temperature, then let it sit at about 200-250 degrees F for a couple hours. Room temperature resins do not do well at high temperatures, but if you expose them to elevated temperatures (not so high that is bubbles the resin) then it increases maximum service temperature, strength, and stability of the resin in most cases. For this application I would go with a laminating epoxy resin, as most I have seen have higher maximum service temps than most polyester or vinylester resins. Hopefully heat won't be a problem since the silencer can stays much cooler than other parts of the exhaust.

You are right. I am stretching it here. I did some testing on the poly resin I like using. When I made this with poly......

IMG_0626.jpg

I came out ok.......With a little browning...But it was resting directly on the core exit of the muffler exposed to the hot gasses directly. Also....The front and end caps will be made from stainless plate...not a billet aluminum block. Therefore the stainless does a great job acting as a heat isolator as compared to aluminum. Then finally the dimensions will rough`ly be 6x5 inches......so farther away from the hot core. That said...you never know how it will work till you try.....🤣 I will try my beloved poly first....Just because I have it on hand...... I know the pox have a edge in the heat tolerancy.......But I don`t mind making it over if it don`t work.....:doh::snore:

Erling

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You are right. I am stretching it here. I did some testing on the poly resin I like using. When I made this with poly......

IMG_0626.jpg

I came out ok.......With a little browning...But it was resting directly on the core exit of the muffler exposed to the hot gasses directly. Also....The front and end caps will be made from stainless plate...not a billet aluminum block. Therefore the stainless does a great job acting as a heat isolator as compared to aluminum. Then finally the dimensions will rough`ly be 6x5 inches......so farther away from the hot core. That said...you never know how it will work till you try.....🤣 I will try my beloved poly first....Just because I have it on hand...... I know the pox have a edge in the heat tolerancy.......But I don`t mind making it over if it don`t work.....:doh::snore:

Erling

Give it a shot, I'm eager to see how it comes out. I doubt heat will be much of an issue, if anywhere it will be near the front end cap. Aluminum has a higher coefficient of convective heat transfer than stainless, so it sheds heat much much faster than stainless (hence why aluminum is used for radiators). You might want to look into aluminum for the front end cap to see what difference it makes.

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Erling,

If your resin can't handle the heat, I've got an oven and prepreg just laying around that you could use.

That sounds great. I will keep that in mind as I go along. I wont know till the end....But we shall see...:doh::snore:

Erling

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Give it a shot, I'm eager to see how it comes out. I doubt heat will be much of an issue, if anywhere it will be near the front end cap. Aluminum has a higher coefficient of convective heat transfer than stainless, so it sheds heat much much faster than stainless (hence why aluminum is used for radiators). You might want to look into aluminum for the front end cap to see what difference it makes.

Yeppers...... I did look into the front endcap aluminum......but it would cost a fortune just to custom make the billet piece to specs......And it would only transfer more heat out to the carbon fiber. I was a little nervous when I made these two.......

IMG_0007.jpg

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Since the stator gets really hot........But it held up.....and is still holding up great. I used a infrared thermometer, and found that the stator case saver in fairly close in temperature exposure to the muffler skin.....We shall see.....

R/D is one of my favorite subjects.......:doh::snore:

Erling

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Hey, why are you online? Get out there in the garage!! :banana:

:doh:

Heading out there right now......:snore:🤣

Did you install the screen saver???

Erling

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Hey erling what do you think your bike weighs with allthe CF work you have done? Compaired to the original plastics are the CF parts more rigid against wind at hwy speeds? All in all I would love to hear the observed pros and cons of a drz incased mostley in CF?!

Cheers and thanks Logan

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Hey erling what do you think your bike weighs with allthe CF work you have done? Compaired to the original plastics are the CF parts more rigid against wind at hwy speeds? All in all I would love to hear the observed pros and cons of a drz incased mostley in CF?!

Cheers and thanks Logan

The parts are on average 50-70% lighter than the plastic they replaced. But yet again...I welded the SS rack and sowed the bags....That added I`m sure 10 lbs...Taller seat windshield fairing......I weighed it last month... 324 lbs with 4 gallons of gas...and 300 even no gas......So it`s no lightweight....But that`s never been my goal. As far as the rigidity.....Much stiffer and stronger than plastic.....I remember my front fender hula hopping through the air at highway speeds.......Rock steady.....:doh::snore:

Erling

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You might wan`t to don a pair.....make that two pair of sunglasses and drink a beer or two before proceeding.........🤣:banana:

First I cut the end caps in SS to use as a pattern for the franken muffler...test one.....

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Then I cut the sheet metal for the franken muffler test.....

IMG_0107.jpg

Then began building the test subject.......

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With packing in hand I started stuffing the ugly duckling.......

IMG_0110-1.jpg

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And here it is installed on the bike......Hold on to the chair pleazzzzzzz...:eek:😛

IMG_0112.jpg

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Perhaps I should underscore that this franken muffler test subject was build for the purpose of testing.......not riding...... So I wanted to see what could be gained by using a 20 inch long core instead of the 14 inch MRD/SSW....and instead of 3/4 inch packing....i have between 1 1/2 and 2 inches of packing......... I must say that I`m very satisfied with the results.....I am hosting the video as we speak....and it should be available shortly......So fetch another beer and a welding mask....we`ll see you back here shortly....:doh::snore:

Erling

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