Kevlar exhaust sleeves, bulk order needed

[micpec]

Ok, I hope my info on this helps our ideas a bit further. Currently I have a good kevlar JHA end can that is fitted on my project bike. It will be harsh to get that dismantled as it is still in good working order, in great condition too.

On the other hand, I already have dismantled one of my TSR carbon end cans, it is one that goes onto the Ti SP1 system. I can get precise measurements of this TSR end can but sadly not sooner than this weekend (not earlier to due busy schedule and other commitments)....is this okay, Chris/Tony? Need to find it as I packed it in one of my parts boxes Also, I will check the data for more specs regarding the various brands that produced kevlar cans before in Japan. Maybe better to specify what exactly measurements is needed?

The kevlar woven cloth I can arrange comes in 175gr/m2 thinkness and either 1m2 upto 50m2, also in band width 50mm and 100mm. Although not cheap but very nice.

[Variablevalves suck]

No rush on the measurements. I just need a lenght and the internal dia of the carbon tube so as an accurate mandrell can be turned. I dont want to buy a lenght of ally, get it machined and then find out its too small.
I should be ok with the cloth, i already have some carbon/kevlar mix that Tony thinks is correct so just need to get a pre-peg in the same weave.

[micpec]

@Chris, Tony,

The diamensions of the TSR carbon cans are as following:
* Length of the carbon TSR SP1 can sleeve = 400mm
* Inner diameter of same sleeve = 98.2mm
* Outer diameter of TSR inlet and outlet caps = 97.2mm
* Inner diameter of internal perforated tubing is 35.5mm
* Length of internal perforated tubing is 400mm

After checking the TSR caps I recall my previous input regarding the material that is made off. The inlet cap
is 100% for sure stainless steel. But the end cap of the TSR cans that comes with the TSR Ti is indeed made from Ti (Tony, you are correct on this )

So, can we get these kevlar sleeves made soon, guys?

[Variablevalves suck]

Right, ive got the shrink tube to go so will pickup some 100mm ally monday and machine to size then just a matter of finding some prepeg, lets hope its that easy!

[Variablevalves suck]

Should be up and running by the weekend as the mandrel is in the lathe as i write, so as soon as i get it back i will have a play about.

[micpec]

Okay, Chris. Let us know the outcome.

[Variablevalves suck]

Well, beat me with a broken bottle, my balls are feeling a little weighty right about now.
Been playing with this carbon/kevlar stuff over the last couple of hours and it just might work.

Forgot to take a picture as the cloth was being applied but remembered the camera after the shrink tube had been applied.

It was serious head rush stuff as the fuse popped on my hot air gun as soon as i started.

No this is not a sample for the doctor but the learning curve was running high, note to self use a lot less resin. I could have done 10 with the amount i made but i was worried about not having enough at the start so went a little large and had this left over.


So, with the sleeve removed it looks flippin good, there are a couple of marks that i think are due to the gun packing in at the important point in the layup but its very usable and 98% there so as a first attempt im over the moon.

I have not attempted to remove it yet, may need to cool the ally core in the fridge but will leave it till tomorrow and may be take it up to the men in the know for a little advice.

[Drunkn Munky]

Who da man

Nice work chris, I can't believe a finished sleeve is in sight!

[micpec]

Good job, Chris. I am curious to the next ones...must be a way to improve it

[Variablevalves suck]

Ive got to get it off the mandrel first! I think it will be a lot easier second time around and i will have two of everything next time.