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Author Topic: CF muffler conversion  (Read 877 times)

Offline Will Hinton

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CF muffler conversion
« on: January 21, 2008, 11:25:15 AM »
Well guys, it ain't purdy but it's light!  Here's the carbon fiber muffler conversion I just finished for my LA46.  The stock muffler weighed in at a robust 2.75oz and I hate the mess from tongue mufflers so I did my own thing with the old stocker.
I first filed all the cooling fins off and smoothed it down and then molded two halves around it, rear part first and then the front.  I used plastic wrap as a release agent which doesn't give ya the best of smooth, but is very effective.
After the two parts, (not really halves) were done I then sawed the muffler free from the mounting tongue/flange and epoxied the two parts in place on it.  after that cured I slipped a sleeve over the tongue and around the joint between the two parts and epoxied that.  Now it's ready for the post cure process which will happen tomorrow if all goes right.
One hour at 150, an hour at 250, one at 350, and one at whatever my home made oven goes to at max temp.  My thermometer doesn't go above 400 and 450 is the proper temp at that stage.  This has worked well for my tuned pipes so should be fine here.
Final weight, you ask?  1.25 oz!  Means I can get a little of the tail weight off my Tutor.
This was a fun and quick project that nicely filled in between finish curinng, etc.
Blessings,
Will
« Last Edit: January 21, 2008, 11:56:37 AM by Will Hinton »
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Offline Randy Powell

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Re: CF muffler conversion
« Reply #1 on: January 21, 2008, 12:59:45 PM »
Will,

I tried this once, though I go a bit more carried away (gee, that never happens   ;D  ).

I used an old ST muffler and just sprayed it with PVA release agent and made a mold from QwikSet molding material. I laid it up with CF and epoxied the haves together. I molded in an aluminum piece that actually contacted the engine. Worked fine for about 20 flights, then I burned a hole in it. I still have the mold somewhere. Hopefully, you have some sort of insulation between the engine and muffler
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Offline Will Hinton

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Re: CF muffler conversion
« Reply #2 on: January 21, 2008, 05:02:58 PM »
I sawed the stock tongue off the muffler and used it for mounting.  Do you think that will be enough?  I hadn't thought about the closer proximity of the muffler verses a pipe on a header!
Could be an oops.   ??? ??? ??? :( :'( :'( :'( :'( ~^ HB~> HB~>
Will
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Offline Randy Powell

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Re: CF muffler conversion
« Reply #3 on: January 21, 2008, 10:35:42 PM »
Will,

One of the reasons that pipes work out OK is the relatively long header that allows the exhaust gases to cool a bit. Even then, it's not uncommon for a pipe to fail and it's usually at the end that connects to the header. My muffler just had a 1/4" chunk of aluminum molded into the end that bolted to the engine and as I said, the muffler failed about 10 flights in. It blew a hole directly opposite the exhaust opening in the engine. Sigh... It was a good idea, anyway.

Just have to try yours. Might work and it might blow out. I would be willing to be that it gets soft after the first flight.
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Offline Will Hinton

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Re: CF muffler conversion
« Reply #4 on: January 22, 2008, 11:28:44 AM »
Wish I could run out & try it now, but at near zero temps the LA might start, but I won't!  My body's starter falls off at 50 degrees!  I'll let ya know come spring whahoppens.
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Offline Randy Powell

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Re: CF muffler conversion
« Reply #5 on: January 22, 2008, 11:47:36 AM »
Will,

One of the reasons I moved from Idaho to Puget Sound was that I got tired of 100 degree temperature swings from Summer to Winter. Where we lived it would get down to zero in the winter with great piles of snow and over a hundred in the summer. I thought, hey, the Puget Sound is fairly moderate. 40s in the winter, 70s in the Summer. Now you're talking. I should have just stood in bed.

I just looked at the forecast for the next 10 days. Humidity up over 75%, temps in the low 20s overnight and high 20s to low 30s during the day and a prediction of yet more snow. Could be a lot more. Yea, looks like global warming to me. I'll tell ya, Tucson is looking better all the time, even if you can poach eggs on the sidewalk in the Summer.
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