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Cutting down a carbon fibre muffler

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  • frenchie
    replied
    Originally posted by dwillia View Post

    How did you go? and nice to meet you - sorry I was the walking dead!
    So! finally all done, what a mission. disassembly wasn't too bad, but the cutting was a bit of a mission, the inner tube to the carbon was a lot tougher and has a like steel wool weave too, didn't do a perfect job but at's all on the inside now haha. Main muffler section was 35cm now 18cm, so JUST over half as big. That big bag of packing you gave me, ALL of it fit into the shortened can, just kept packing tighter and tighter.

    The bike sounds INCREDIBLE now. I was expecting a volume increase, and at idle/cruising rpm/throttle it really isn't much louder at all, but boy under hard acceleration it has much more of a bark to it and the whole note/tone has changed drastically and it sounds WILD. I am incredibly happy with the result. The bloke that helped me do it also fixed my quickshifter cable, so with that working again, new bars on and the new Zorst, you better believe the ride home was cheeky.

    many thanks again everyone for the advice along the way, and big shout out to dwillia for gifting the packing!



    Last edited by frenchie; 05-08-2019, 08:41 AM.

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  • frenchie
    replied
    Anyone know where in Perth I can get the stainless steel gas tight rivets for exhaust repacking?

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  • frenchie
    replied
    So I still didn't get it done when I said I would, current plan is this Sunday. I did however get news bars on the Zed and love it, Protaper contour carmichael bend.

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  • frenchie
    replied
    Originally posted by dwillia View Post

    How did you go? and nice to meet you - sorry I was the walking dead!
    No sweat mate this winter has been crazy in that regard. Many thanks again for your kind generosity!

    So the plan is to attack it this weekend, so I'll be taking pictures along the way and should be all done by Monday to post some results and thoughts on it.

    In an unrelated blunder I managed to slice the quickshifter cable that joins the pressure sensor in the shift rod to the body of the unit where you set the cut time, so that also gets a professional repair this weekend.

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  • dwillia
    replied
    Originally posted by frenchie View Post

    Honestly that'd be ace if you don't need it? happy to pay in cash/beer etc if you like.

    And yeah I envisioned using masking tape too, and perhaps a spray bottle of soapy water or something to keep the dust and heat down during the cut.
    How did you go? and nice to meet you - sorry I was the walking dead!

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  • dwillia
    replied
    yeah use those ultra thin cut off blades - I have a stack if you want one when you pick up

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  • dwillia
    replied
    Originally posted by frenchie View Post

    Honestly that'd be ace if you don't need it? happy to pay in cash/beer etc if you like.

    And yeah I envisioned using masking tape too, and perhaps a spray bottle of soapy water or something to keep the dust and heat down during the cut.
    nope just swing past anytime this week and grab it

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  • SomeBloke
    replied
    I've cut carbon loads:
    • masking tape on every cut, helps stop splintering
    • wear a dust mask and if you keep it moist it will help keep the dust down too
    • Long sleeve shirt/cover skin. The dust gets itchy.
    • Easiest way on a budget is to get the $50 bunnings special Dremel and the cutting discs. Will make light work of it. You don't need a fancy blade, especially for a one off.
    • When done, lightly sand the edges with a fine sandpaper, 400 or so. Tidies up the edges and helps prevent splinters
    • Optional, run a light bead of resin around the cut edge to seal the cut, again, helps prevent splintering. Could probably use some 2 part epoxy araldite (clear) from bunnings.
    Packing: it's all much of a muchness, when I was building and testing muffles using a CBR600 engine, we found that how hard/tight you packed attenuated each frequency differently. Our go to was stainless steel wool wrapping the perforated tube, then wrapping that in the glass and finally using some rockwool to help keep the heat away from the carbon.

    Point of caution. If the packing isn't quite perfect and hot gas can blow directly onto the carbon, it will eventually burn.

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  • frenchie
    replied
    Originally posted by dwillia View Post
    I have an unopened bag of packing I bought from Cullys a while ago - You're welcome to it if you want.

    When I've dealt with material likely to splinter, I've used a good quality masking tape applied to the surface, place your cut mark through the centre of the tape
    Honestly that'd be ace if you don't need it? happy to pay in cash/beer etc if you like.

    And yeah I envisioned using masking tape too, and perhaps a spray bottle of soapy water or something to keep the dust and heat down during the cut.

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  • dwillia
    replied
    When I've dealt with material likely to splinter, I've used a good quality masking tape applied to the surface, place your cut mark through the centre of the tape

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  • dwillia
    replied
    I have an unopened bag of packing I bought from Cullys a while ago - You're welcome to it if you want.

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  • Heretic
    replied
    Another thing is, especially thin carbon fibre is very brittle and being fibreous can split and delaminate from the cut if your rushed or heavy handed so make sure you cut it with a recommended disk or saw blade and do wear PPE. Old or weathered or badly laminated carbon fibre probably more so.

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  • frenchie
    replied
    Originally posted by Water pig View Post
    Cutting carbon fibre is easy enough with a grinder/drop saw make sure you don't breathe the dust. I've never really noticed any real world difference in packing brands. I'm happy enough to help you with the job but I can't do it until at least Monday
    I appreciate the offer! it wouldn't be for a few weeks yet anyway, I have yet to even order packing, but I'll keep you in mind, cheers for the offer and advice!

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  • Saltie
    replied
    G’day Frenchie , I work in granite trade, I’d use a continuous rim diamond grinder blade, you can get them Bunnings, whist your cutting get a spray bottle with a fine mist with a wee bit of detergent in it, this will keep the heat down an less dust .as always ppe is always a plus.
    be sure that the piece your working on is adequately secured .

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  • Water pig
    replied
    Cutting carbon fibre is easy enough with a grinder/drop saw make sure you don't breathe the dust. I've never really noticed any real world difference in packing brands. I'm happy enough to help you with the job but I can't do it until at least Monday

    Leave a comment:

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