I know this should be in the "how to" section but I haven't got enough detail with pics, etc. I'll post more pics as I go but here's what I have so far.

I used PVC down pipe wrapped in non porous teflon sheet. Wrapped satin weave glass cloth about three times around the pipe then one layer of carbon fibre. I should have taken pics of the wetting of the cloth to show how I did it between two layers of vacuum bag plastic. Might set something up at work to show you guys. I had issues with vacuum (check the guage, nothing showing!!!!!!!!!!!!) so I had to stand there squeezing the bagging tape till it held for a bit. Turns out the bagging tape is too old and has lost it's ability to stick to the plastic. The resin I used is a high temp epoxy made by HYSOL called EA956....expensive stuff. Anyway, here it is under vacuum (well, not yet).



Here it is after de bagging and cleaning up the ends after I cut it down to 10 inches.



Next job is to make up the parts for the end cap and the end that joins up to the headers. might use titanium and get a dude I work with to tig weld it all up for me. I'll get the perforated tube for the guts from a muffler shop. More pics to come.

 

looks good man... have thoughts on making one myself.... (for sales)

keep it up

 

What do you think so far? Obviously got to make and weld in the entry and exit pipe but too impatient so I'm posting more pics. Next one I make will be kevlar but in an oval instead of round. Round's boring.
The first two are after sanding off excess resin and show how the end caps were made.

 

Got carried away and G clamped it in place to get an idea of what it will look like. Crap phone photo but you get the picture.

 

Looks good!

 

i'm liking the progress

 

Awesome job so far. Gonna drop a resonator in there somewhere? Or are you just making the can hollow? Loudddddddsauce.

Edit: You said it under one of your pictures. Your dude from a muffler shop is gonna hook you up.

So I guess just "Awesome job so far!" Haha. Keep up the pictures

 

Yep, perforated tube wrapped in four stroke muffler packing that you can get for MX bikes.

 

hey pepper looks great so far man...

tell ya what you think round looks boring but i disagree....

it looks fine as long as you compensate by adding a different design tip...

like they do with the devils for the r6 (like i have on my bike)

notice how the tip isnt round

http://www.youtube.com/watch?v=AFPqIWjp02g

but jmo hah

 

Nice work Z. Yeah, oval tip really does make a big difference. Here's some more pics of what I did today. I thought the mounting strap was way too wide making look bulky so I slotted it. The edges look a bit messy because the blade I used to trim the rubber liner was a bit blunt. My brother is going to get me some stainless steel aircraft fuel line tubing with different bends in it so I can cut and weld in what I need.