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Old 05-01-2012, 04:59 PM   #61
ebrabaek OP
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Joined: Jan 2010
Location: Grand Valley, Colorado
Oddometer: 4,674
One inlet cap cast.....


The parts are stacking up....But I'm fraid this is it...until Friday......




Erling
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Old 05-01-2012, 09:12 PM   #62
zgfiredude
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Location: Aspen, Colorado
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How dare you stop now!


Travel safely.......
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Old 05-01-2012, 09:29 PM   #63
ebrabaek OP
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Originally Posted by zgfiredude View Post
How dare you stop now!


Travel safely.......
Thanks amigo...

Erling
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Old 05-02-2012, 01:25 AM   #64
jackass dave
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cant you come back earlier ,im waiting for this one ,with baited breath (not bad breath) looking great as usuall.
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Old 05-02-2012, 06:57 AM   #65
ebrabaek OP
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Originally Posted by jackass dave View Post
cant you come back earlier ,im waiting for this one ,with baited breath (not bad breath) looking great as usuall.
I better go.....as this is my real job that finances my Carbon fiber " hobby"...... If all goes on schedule I will pick it up on Friday.....



Erling
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Old 05-03-2012, 05:45 PM   #66
ebrabaek OP
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Ahhhhhh.... back home...... After...well...several states....Could'nt id a big lake in MO.....dang...Gotta find out..... Never the less.... 5 pounds of fresh roast Texas blend arrived, from Texascoffeeroasters.......I am armed and dangerous.... In the am we go......

Erling
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Old 05-04-2012, 08:06 AM   #67
rediRrakaD
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5 pounds!
So you stayed up all night and are done right?

Enjoying another trip down the Ebrabaek carbon rabbit hole.
Thanks for posting!

S.
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Old 05-04-2012, 09:01 AM   #68
ebrabaek OP
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Quote:
Originally Posted by rediRrakaD View Post
5 pounds!
So you stayed up all night and are done right?

Enjoying another trip down the Ebrabaek carbon rabbit hole.
Thanks for posting!

S.
....... That would be some Crazy espresso brew...... My wife only allow's two doublos twice a day..... I think she knows what happens.... Like garaging all night........

Erling
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Old 05-04-2012, 09:08 AM   #69
ebrabaek OP
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Next is to drill the whole for the intake coupling...... If I can just say two things here...... Careful.....and go backwards......... If you go forward the teeth will rip the piece out of your hands.... you will then put it in a vise..... it will now shatter.... So easy and backwards... Take your time, and the cutter will slowly score itself through.....


Then insert the coupling. I cut the hole 1mm too small, and sanded the rest...to get a tight fit....so the coupling will be held in place for correct alignment.....



On the pipe.....



Then I taped the shell on....to align the coupling, and make sure the muffler have no clearance issues....




Next...... Bonding the coupling in place.....and Fitting the cap to the shell....

Erling
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Old 05-04-2012, 11:08 AM   #70
ebrabaek OP
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Inlet cap taped off, to prevent resin from escaping though the small voids.....and to hold it in position during curing....


Then ready to bond.....


A few words on the work inside. Remember the inlet was cast from a foam plug.... So if you back up a bit...you could have cast it so after the 4 layers of composite....it would have fit into the shell..... I like to cast a few mm's bigger, and then sand it into shape... So I added 4 layers along the top of the cap where the rivets protrude....Jut to make sure when I begin removing material for the fit into the shell....I have enough material..... I then mixed some cyt fibers with resin....dapped it into the seam between the cap, and the coupling....covered that with a few 2x2 inch cut carbon fiber pieces.... Now curing.....




Erling
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Old 05-04-2012, 02:23 PM   #71
ebrabaek OP
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Cool2 Fitting the inlet cap.....

It fit's...... After some careful belt sanding.... 1/4 mm at a time.... the edges was sanded....and it now fits with only very small voids....




On the bike the angle is perfect,as it did not move during curing.....





After 2000 wet sanding....


After a hand rub of HTE epoxy....


One light inlet cap....as compared with either s/s...or aluminum....


All the parts so far....Inlet cap....outer shell....2 bands... and the core ( core is curently 20 inches long so will be chopped to 16).... Not bad at just under a pound...with the end cap...packing hanger, and 6 inch less s/s core....




Erling
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Old 05-04-2012, 08:02 PM   #72
zgfiredude
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NIce progress......are you going to work on the banding next, or the core/endcap/and then the banding?
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Old 05-04-2012, 08:58 PM   #73
ebrabaek OP
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Quote:
Originally Posted by zgfiredude View Post
NIce progress......are you going to work on the banding next, or the core/endcap/and then the banding?
I would like to fit the inlet tomorrow....and rivet it in.....then begin on the end cap..... Perhaps the mount band, as the front and rear band are already fabbed.... Have fun DC'ing

Erling
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Old 05-05-2012, 11:43 AM   #74
ebrabaek OP
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So....as promised... The inlet cap is fitted......


Then I drilled a small hole on each straight away section......then the final size hole to accommodate the 5mm aluminum rivet....added a aluminum washer on the inside to take the stress of the composites......Taking great care not to disturb the position. Fitted the pipe after each of the first three rivets were installed....




The mating surfaces are done really well....and there are very little voids in there. That is not easy to accomplish.... But I'l take it....


Then back on the bike.....I like.......


Remember...the aft side of the shell is sloping to accommodate the fuel tank clearance.... so a dab of high temp, silicone, just enough to seal the seam from the inside... rather than coating the whole flange of the inlet cap.. It becomes impossible to remove later if need be.... This way you just cut the seal from the inside if you ever need to remove the inlet cap...... Don.t ask how I know this.....


With the front end now done.... Work can now begin on the end cap...... Yay... I see the light...and it's not a freight train .....

Erling
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Old 05-05-2012, 04:30 PM   #75
ebrabaek OP
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As the day draws to a..." sit and relax sipping espresso" time.... The end cap was made in foam as well.....




Hard to make out the angles in the foam.... But I have a surprise...... and will reveal it when casting the exit pipe.....
Until then....

Erling
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