What grade of aluminum?

Discussion in 'The Garage' started by DavidR8, Aug 18, 2019.

  1. DavidR8

    DavidR8 Wanna-be ADV rider

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    I have a Two Brothers exhaust can with a hole in it. It’s really more than a hole, it’s like a big gash in the side. IMG_5176.jpg

    The inlet and outlet pieces are in perfect condition but my bikes PO somehow managed to have this happen.

    I don’t want to just chuck the thing so I’m wondering two things:
    1) could I fashion a patch?
    2) could I fabricate a new can and put the inlet and outlet in the new tube?

    What grade of aluminum sheet would be the easiest to work with?

    Edit: a bit of Google-fu indicates that 3003 or 5052 would do the trick. 6061-T6 is not recommended.

    I’ve taken it apart and it’s nothing more than an aluminum tube with a baffle and packing inside. So low tech it’s almost laughable.
    #1
  2. tbarstow

    tbarstow Two-wheelin' Fool Super Supporter

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    Find a 1000 or 1100 aluminum sheet.
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  3. slacker1965

    slacker1965 .....no matter where you go......

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    If you are going to replace the tube, just replace it with a tube instead of trying to make one. Lots of inet sources of tubing, eBay is easiest but there may be better/cheaper sources.
    If you live in a decent sized city, & have one, many metal suppliers will sell their 'drops' cheap.
    In case you don't already know this, you will need to know your desired inside diameter to match your cones, & desired wall thickness.....
    You could always upgrade to stainless steel, but it isn't cheap
    Either way, good luck with your repair
    Peace
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  4. kantuckid

    kantuckid Long timer

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    Looks like a previous patch got hammered.
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  5. nickguzzi

    nickguzzi Long timer

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    Second the stainless swop.
    Depends on the grade, some grades can difficult for a novice to drill for example. Much less likely to get damaged while fitting or forcing into place though.
    You can get away with thinner material to offset weight gain.

    I live near a small rural town ie country - farming - growing - food - processing. We have quite a few stainless manufacturers/fabricators. I had a worktop made for my hob unit, very precise as you would expect from a laser. Nicely welded corners, whole thing looks and works like a charm.
    Cost around $150.
    Most places have workshops that can make what you need, especially if you can be a bit flexible. It is not beyond the bounds of possibility that the tube you need is a fairly standard size.

    You can also buy carbon fibre in tube form.
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  6. Salsa

    Salsa Long timer

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    I would use 6061T6, the most common. 1100 is usually soft,soft,soft. Too soft for me.

    Don
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  7. anotherguy

    anotherguy Long timer

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    If you must 2024 will do the job. But is it really worth it?

    You can get 12"X12" hardened 2024 for $20 USD from Mcmaster.
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  8. Beezer

    Beezer Long timer Supporter

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    not 1xxx series... too soft. unless its really thick, you can dent it with your finger. if you have a local fabricator shop around they usually have scrap that is cheap or even free. if you want to hand form it find a piece of pipe the right diameter to wrap the sheet around. a little smaller is better than too big. break (slight bend) the front edge about 1/2" so it will lay flat. maybe straps to help pull the metal into place.
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  9. nickguzzi

    nickguzzi Long timer

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    If you can only get larger sizes, get one big enough you can cut, then overlap and rivet (presuming you can't weld) Use hose clamps to hold at right size.
    If using rivets, use the usual Al ones for Al and steel ones if you go for stainless. Stainless rivets are fairly hard to set by hand, choose the small size.
    And you can get so called waterproof rivets too, to stop seepage.
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  10. shovelstrokeed

    shovelstrokeed Long timer

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    You just might try ordering a replacement can from 2 bros. They could have something in stock.
    #10
  11. DavidR8

    DavidR8 Wanna-be ADV rider

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    Good idea. I’m in conversation with them.

    Edit: Mark Jacobs is emailing me.
    President of Two Brothers!
    #11
  12. Zahnarzt

    Zahnarzt Crashes Much

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    What caused the hole?
    It looks like a recurring issue.
    #12
  13. DavidR8

    DavidR8 Wanna-be ADV rider

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    It’s in a new-to-me Honda Hawk. I suspect the can may have come from another bike as I don’t think there’s a way the chain could have done that on this bike unless the can was actually falling off the bike.

    The damage is about 12”-14” above the chain and is completely parallel to the chain line.
    #13
  14. kenny robert

    kenny robert Long timer

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    what are the dimensions i have lots of core aftermarket bodies and some very nice condition
    wall thickness and a precise circumference and length
    if oval ,round can be easily ovaled but must start out with the same circuference at a given wall thicness/gauge
    #14
  15. kenny robert

    kenny robert Long timer

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    me i would l;ook for a used aftermaket can with simil;ar internal dimensio\ns ans a direct slip on fit size or a schosh bigger
    i have for \xample a akrapolish ti aftermarket can off a 450 mxer that woluld so cool on there you could get hookers for free
    #15
  16. Carlos M

    Carlos M www.motoxplorers.com

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    I had a broken chain cut a slash like that through a Wings Ti can on a 990 KTM. It makes you think what other damage may that cause should it touch ones body.
    #16
  17. Wentwest

    Wentwest How's that work?

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    I had a broken chain bend a shifter shaft enough that it always leaked oil past the seal.
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  18. DavidR8

    DavidR8 Wanna-be ADV rider

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    I just measured it.
    It’s .080 thick
    Exactly 14” long

    Oval: 5” tall x 3.75” wide.
    #18
  19. DavidR8

    DavidR8 Wanna-be ADV rider

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    Turns out Mark Jacobs, President of Two Brothers Racing is sending me a new aluminum sleeve and repack kit to use with my end caps.
    What amazing customer service!
    #twobrothers
    #19
  20. kantuckid

    kantuckid Long timer

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    I was going to say this: by the time you run around chasing metal while burning gasoline it might make sense to buy a new can or a barely used one like the Delkevic I have listed in the FM. It is a welded, UK built, SS can w/removable DB killer and universal clamps.
    #20
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