DIY Carbon Silencer Repair

[silverstrom]

Maybe it's because I'm cheap, or maybe I'm just practical. Whatever the case, I hate to throw away anything that I think I can repair or repurpose. I've had these Jolly Moto cans here for 4 years and was trying to figure out what to do with them. This is what I came up with. Not perfect, but not bad. A new pair of carbon cans here is $595 Cdn with shipping and taxes. This, or course, is but a fraction of that cost. Maybe I am cheap.

[Matty]

Nice.
I wouldn't have thrown those cans out either, great solution.

[Vin]

Great job mate they look just the job

[adr1an]

They look great. Nice job. Is there anything special about the carbon wrap and where did you get it from? Did you have it specially cut and what's the thickness. Sorry for all the questions, but they look damn good and I have some I'd like to do.

[silverstrom]

http://www.ebay.ca/itm/Real-Carbon-Fbre ... RTM2067269" onclick="window.open(this.href);return false;

The seller will cut it to your needs if asked. Different thicknesses also. I just got more in a larger size to make side covers for a project.

[adr1an]

Much appreciated. Have you used the 0.3 thick?

[silverstrom]

Yes, 0.3 mm.....any thicker and I don't think it would work for silencers. 0.3 is flexible enough to bend, but rigid enough to take the rivets and not crack. To get the carbon to conform to the can I use large gear clamps. I used 4 for these cans, equally spaced. That holds it all nice and tight so it can be drilled and riveted.

My next plan involves laminating these carbon sheets to 1/8 inch ABS sheets to make panels.

This carbon is also good for clock surrounds. Many uses really.

[MK]

You're not a cheapskate, you're just responsible with resources
The only issue here will be the next re-packing. It'll be a bit more effort to disassemble them because of the dents and burrs on the rivet holes.

The RZ350 F2 models for example often have damaged cans, but there's no option for exchange as they're welded.
There I've often seen this kind of repair either with aluminum or stainless sheet/tube material.
People who prefer a bit more "bling bling" on their bikes could polish, others bead blasted the surface or used it "a la nature".

[silverstrom]

Good point Martin. I did think about that before starting.Those cans had maybe 200 km on them before they were damaged several years ago. I pulled them apart before riveting and the original JL packing, more of a woven wrap really, was perfect and clean. They will never need repacking as long as I own the bike.

I'll be pulling this bike into the shop soon to install a modified clutch cover and do a few other small mods. I may try the wrapped cans to see if I like the look. I did have carbon cans in mind when I built the bike, but couldn't justify the almost $600 cost for 2 cans.

[fozzy17]

is that a 3xv rear end on the rd?