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Old 02-05-2011, 11:54 AM   #31
brianwheelies
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For pictures I use a Facebook account just for pictures. No personal info or anything.
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Quote:
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Adding a turbo or supercharger doesn't automatically turn an engine into a Palestinian alarm clock.
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Old 02-05-2011, 01:23 PM   #32
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Quote:
Originally Posted by Tommy_J View Post
Anybody know the secret to uploading more than one pic at a time?
If you are uploading from your computer, the limit is one at a time.
If the hosting is done elsewhere (Smugmug, Flickr, Facebook...) you can attach multiple pix to a post.
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Old 02-05-2011, 07:01 PM   #33
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Thanks for the advice on posting pics. The exhaust housing has been machined to make ears the muffler can bolt to. While I was at it I machined some excess metal out of the housing. Then the entire housing was sanded with a flapper wheel until smooth. This way it will look good if I ceramic coat it.

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Old 02-05-2011, 07:12 PM   #34
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Well now, just get right started, why don't ya!
Dig the one piece mount, muffler and masking.
The muffler profile is so "stock" looking, just paint it flat black when you are done to compete the appearance. Might want some extra heat reflector on the side panel to keep it from melting, its gonna get a bit hot under there.

Probably want a shield where turbine body protrudes too, otherwise you will get the classic KTM dirtbike pants/boot burn.

Thinking of moving heat, would ceramic coating the inners of your muffler box and core help lower temps around/outside the box?
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Old 02-05-2011, 07:27 PM   #35
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Snow, Your right, some thought and effort will have to go into heat management!

The part of the "muffler" that goes over the turbo will probably become part of a heat shield.
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Old 02-06-2011, 07:17 AM   #36
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Alright lets see if I can upload images from a host.

Here is a series showing development of that muffler bracket. It was laid out on poster board, test fit, re-laid out, re-tested, modified some, transferred to steel, band sawed out, folded, and tack welded in place. A pleasant 20 minute job.

.













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Tommy_J screwed with this post 02-22-2011 at 04:53 PM
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Old 02-06-2011, 07:45 AM   #37
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The length of the muffler was trimmed down, front and back. It got a serious slash cut. Maybe longer would have looked better but the turn signal was in the way. I considered making a new tail tidy type thing to move the turn signals, but that's the sort of scope creep that would set the project back a week.

Just to state the obvious, this is a mock up. Its not done by any means.

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Old 02-06-2011, 07:51 AM   #38
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The metal cut off the turbo end of the muffler will be saved to make a heat shield latter. Hence the notch around the wastegate arm.

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Old 02-06-2011, 10:51 AM   #39
cpallen
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Suggestion

Put each image link on it's own line, and you can insert your descriptive text in between eg:

[IMG link # 1]


yada yada yada
The length of the muffler was trimmed down, front and back. It got a serious slash cut. Maybe longer would have looked better but the turn signal was in the way. I considered making a new tail tidy type thing to move the turn signals, but that's the sort of scope creep that would set the project back a week.

Just to state the obvious, this is a mock up. Its not done by any means.


[IMG Link #2]

more description

[IMG Link #3]

etc
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Old 02-06-2011, 11:22 AM   #40
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CP, will do. This is my first build thread - ever. I'm learning as I go.

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Old 02-06-2011, 11:51 AM   #41
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As a guide on how to design a muffler I dug up these pics. When this SM was two days old I cut the muffler open and "de-catted". The results were very satisfactory, but as I said before I like my bikes quiet.



While the mufflers were cut open the baffle design was visible. It's hard to see, but there are three baffle tubes separating the muffler into two chambers. After that the exhaust flows out one tail pipe. BTW, that thing on the right is the catalyst. I was surprised how small it was.



My objective is to package a similar design into this space.

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Old 02-06-2011, 12:00 PM   #42
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Quote:
Originally Posted by Tommy_J View Post
CP, will do. This is my first build thread - ever. I'm learning as I go.

And you are doing a great job! I'm riveted and don't even like KTMs.
You are obviously a brilliant craftsman.
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Old 02-06-2011, 12:38 PM   #43
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The only thin wall pipe of the right diameter I could scrounge up easily was fencing material. Its very low strength alloy. That's fine though because it easier to form bell mouths on the the baffle tubes.

Here the pipe is being rolled around breaker bar handle.

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Old 02-06-2011, 01:57 PM   #44
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BTW, this was the plan for the first tube in the muffler. It has a taper the fits tight against the turbine housing and that's what really locates the muffler. That reduces stress on the three little ears which just snug the muffler against the turbo.

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Old 02-06-2011, 04:10 PM   #45
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I sure would like to sponsor the materials for a second get'up mount and tubing, since yer just slappin' it together so quick. Of course, I would have to save up extra to buy the matching whistle, but I could manage. Then I would just have offer to mount it on my bike, you know, fer the sake of enjoy'in it.

Wadda'ya say, shall I start flooding your paypal account with $1 biils?

All right I'll stop bother'in ya with nonsense and let you get the real work done.
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