Diy expansion chamber exhaust

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Diy expansion chamber exhaust

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Unlocking the secrets of 2 stroke expansion chamber exhausts E1

Results 1 to 9 of 9. Thread: How to build an expansion chamber.

diy expansion chamber exhaust

How to build an expansion chamber. Really interesting way to build an expansion chamber. Crazy, All I need is a hydraulic pump that pushes psi. I think someone posted something about that a while back.

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Really cool stuff though. Ive hand rolled one before and it sucks, and the hydro formed stuff looks sooo much better.

I've been on that site for a few years. Good people too! Rebuilt my bike from that site. Beautiful bike man I have wanted an rd, rzsuzuki gammah1, h2, h3 or the like for soo long.

I've never come across a deal at the right time. How does it run? Runs excellent! Been working on different pipe styles for power ranges and these pipes rock, get lots of midrange and top end. Similar pipes with the larger mids produce alot of top, only good for WOT. Stockers give a good low end to midrange and no top end. Have some old Bassani's going on this summer. Excellent job on those pressure formed pipes.

How Two-Stroke Expansion Chambers Work, and Why You Should Care.

Guys, Here's another good article to reference when hydroforming expansion chambers. Moore refers to a pump he used that was made by Perfecto Products. I believe this is the pump used in the article. Join Date Nov Location southern oregon -- 2,Forums New posts Search forums.

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diy expansion chamber exhaust

Register now! It's free and easy. Show your bike to the world, upload a photo today! JavaScript is disabled. For a better experience, please enable JavaScript in your browser before proceeding. Thread starter Nate Start date Sep 30, Tags diy expansion chamber kludge lo-budget-hi-performance performance.

Nate Member. Joined Aug 12, Messages Stock lo end replacement exhaust -- 18mph Murphy McMonkeyPatcher kludge pictured below - 26mph!! Last edited: Sep 30, Anybody tried anything along those lines? Arty Active Member. Joined Feb 12, Messages It's so ugly I love it! Arty said:.

diy expansion chamber exhaust

Joined Aug 4, Messages Neptunati New Member. Joined Jul 9, Messages Nate said:. Steve Best Well-Known Member. Joined Sep 22, Messages 1, Last edited: Oct 22, Timbone Well-Known Member.

diy expansion chamber exhaust

Joined Apr 20, Messages 1, View attachment View attachment Clearly, the right way to do exhaust modding involves learning to weld. Any thoughts, tips or experiences you'd wanna share on this? Carl Walichnowski Active Member. Joined Jul 2, Messages Wow I just seen this monstrosity, it has to be a love hate relationship.

Post reply Preview.Every racer of 2-strokes will tell you how important the pipe or expansion chamber, to be more precise is on their bike. There is no other item on a 2-stroke that will affect the performance so much. So, what is an expansion chamber, and how do they work? The problem with such a simple design as the 2-stroke is that it is relatively hard to improve. In attempts to improve performance, engineers have changed the port timing, carburetor size, compression ratio, and ignition timing many times, but eventually they realized that there was little else they could do to get better, more usable, power.

As the engineers gained more knowledge of the 2-stroke and its working principles, however, it became obvious that to increase power they needed to have a method of varying the exhaust port timing. With a piston ported engine the exhaust port is opened and closed symmetrically about TDC top-dead-centerso if you lowered the port to start the compression phase sooner, you automatically kept the burnt gasses in longer, which would then mix with the new charge, for instance.

A system for opening and closing the exhaust port at different points about TDC was clearly needed. After much research and development Russian engineer, Michel Kadenacy, discovered how to use the pulses pressure waves from the exhaust to achieve this. Kadenacy discovered that careful design of the exhaust system could effectively use the pressure pulses to close the exhaust port without needing any additional moving mechanical parts.

Taking this knowledge further, he found that the pulses were directly related to the shape, size, length, and diameter of the pipe and muffler.

Further experimentation resulted in an understanding of how and when to change the pulse direction. Although the 2-stroke is very simple in its operation, the interaction between the phases is more complex.

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For instance, as the piston moves up on the inlet stroke, it is also compressing the previous charge ready to be fired. Therefore, looking at the cycles again, we have the following happening at the same time:. If a returning pulse could push that new charge back into the cylinder just at the right time before the piston seals it offmore power would be produced and less fuel would be wasted.

Although the effect often referred to as the Kadenacy effect will only work over a limited rev range, the useful power gained can be tailored to the application. For instance, a road race bike would need that power in the middle to higher rev range, a MX bike would need it in the low to middle rev range, and a trial s bike at the low to middle end of the rev range.

Having discovered the positive benefits of using the pulses, further research concluded that these pulses changed direction when the exhaust pipe or muffler changed size or shape. These discoveries lead to the expansion chamber system. As the name implies, an expansion chamber exhaust consists of a chamber where gases from the exhaust phase expand into. However, the change of shape of the chamber, as it reduces in size, sets up a pulse that returns towards the exhaust port. If the returning pulse arrives at just the right time, it will push the unburnt gases back into the cylinder.Understanding the different types of internal configuration will help you pick the right muffler for your application.

Motorcycle Exhausts - 2-Stroke Expansion Chambers

In this article we are tackling the age old question of how much of high performance muffler design is based on science and how much is slick advertising? With all the different styles and types of performance mufflers on the market with different sound attenuation strategies, it can get confusing to know what is best for your application.

Starting from the top we should define what the purpose of a performance muffler is. Performance mufflers have three simple goals for perfect operation.

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First to absorb and dissipate. Second to move exhaust gasses, and finally to maintain power and performance of the engine while achieving the first two goals. That then reflects the sound wave back upon the next sound wave entering the mechanism all without interrupting the exhaust flow. Each muffler is designed and tuned specifically for the vehicle it is intended for taking into account everything from cabin volume, to exhaust length, to desired level of exterior volume.

Clearly, designing and engineering mufflers that efficaciously contain, absorb and dissipate noise pulses and maintain power with cost efficiency at the same time is no easy task. Nor is it a one size fits all formula. Honestly, the most impressive thing that others identify in an automobile right away is the sound that your car makes. Performance mufflers actually improve the efficiency of the exhaust system and retain most of the power that your engine creates.

Some stock mufflers have been documented to rob 30 or 40 horsepower from a factory high performance V8 by creating excessive backpressure. Adding a performance muffler to your car can also help to reduce wear on engine components, by reducing engine heat and boosting exhaust flow.

Sound is simply a vibration that spreads as a wave through air. In an internal combustion engine, these pulses are created when the exhaust valve opens and the hot gas from the combustion chamber enters the exhaust system.

How quiet can you make a 2 stroke?

The exhaust gas exits the combustion chamber under pressure and meets the low pressure gas in the exhaust pipes and stack up on each other. However, the sound waves migrate through the media without any resistance, making their way down the pipe faster than the actual gases do. If a crest of a pulse wave meets a crest of another pulse wave of the same frequency at the same point, the displacement is the sum of the two waves. In an eight cylinder engine, you can have eight pulse waves at the same frequency at the same point creating a lot of sound.

When these pulses reach your eardrum, the eardrum vibrates back and forth which causes the brain to recognize the motion as sound. It is possible to add multiple sound waves together and get less sound by lowering the pressure pulses. This is where muffler design comes into play. When two pressure waves have displacement in opposite directions there is an interference that occurs. This is the noise canceling effect that muffler designers use on certain frequencies to silence them, leaving only the desired frequencies.

What sounds good is much more subjective. The exhaust note is in the design, not the material. Muffler design types fall into three basic categories: reactive, absorptive, or a combination of the two. There are several other terms in usage today, like turbo, bullet and multiple baffle. Despite the different terms, they still fall into one of these three basic categories: reactive, absorptive or combination.

Certain sound frequencies are eliminated and others are allowed to pass through. The sound waves expand to the outer core of the muffler where the sound waves are cancelled out similar to one of our chambered mufflers. Residual sound waves are then absorbed by the outer thermal barrier which also helps dissipate radiant heat. As the exhaust pulse enters the muffler its velocity is increased using the venture effect.

The increased speed of the exhaust pulse creates a low pressure area behind it. This creates the scavenging effect.How to make an upswept expansion chamber from your exhaust pipe and a second standard pipe from pistonbikes. The program I used for most of the distances and diameters was the 2 Stroke Wizard Pro version 3. The first cone is longer in this design but that is to eliminate the need to make a long B section that gently gets wider the farther back it gets.

The idea here is to be able to fairly easily make an expansion chamber with a peak rpm ofhorsepower between 7 and 8, and have a wide powerband unlike the peaky powerband of a racer.

Below shows the pipe dimensions given by the 2 Stroke Wizard that you can use if you want it to be just right.

The bottom pipe is what I am proposing as an easy to make alternative. How does this DIY pipe compare to pipes available for purchase for this engine? The main two characteristics of an expansion chamber are the length from the piston to the midway point of the final cone, and the angle of the final cone.

The longer it is due to a small anglethe wider the powerband. This DIY pipe has a small final cone angle which gives it a broader powerband, especially necessary for a one speed bike.

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And the length should be made by you to perfectly fit the peak rpm's of the engine. If you do that then this pipe is better than anything offered. Look at how the final cone angle is greater on other available pipes than this one.

That means they have a short powerband for racing with mutiple gears. And they are made to be closer to the engine which means they will offer a high rpm powerband which is not what you want with these engines.

Click here to read how to exactly determine the powerband of an expansion chamber. DIY Expansion Chamber How to make an upswept expansion chamber from your exhaust pipe and a second standard pipe from pistonbikes. After drawing this pattern on poster board add the curves according to their middle height.

Cut out the final pattern, cutting along the curved lines and the two sides. Then use a Marks-A-Lot to transfer the pattern to the sheet metal, then cut it out.

Bend the outer sides of the sheet metal to have a curve, then pull the side ends together, then clamp them in place, then weld the side ends together. Then weld the cones to the middle cylinder, etc. After reading the performance book by Graham Bell I calculated this new pipes peak power rpm as But a standard 48cc Grubee engine has a peak rpm of In order to make the pipe match that rpm this pipe would have to have a longer belly length of 21cm.

For a free on-line pipe dimension calculator that gives similar results as the 2 Stroke Wizard click here. Use these inputs: 40mm bore, 38mm stroke, degree exhaust open duration which should be more if you have raised the port17mm EXD equivalent round exhaust port diameterrpm, 4.Two stroke engines fascinate me.

They are so simple and fun that I've always enjoyed tinkering with them. There are many ways to boost the power, one of which is by installing a "tuned" pipe. The way a two stroke motor works causes them to be fairly noisy and a bit inefficient.

A tuned pipe has a set of cones- Divergent meaning the cone gets bigger and Convergent meaning the cone gets smaller that are built to cause "echoes" or pressure waves to reflect back, which if done properly can increase the power of the engine.

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Check out this link, it will make a little more sense. That's a very loose explanation, but there you go. I've always wanted to build an expansion chamber This is where P. This Piece Of Junk was and is my first motorcycle Somehow, this one snuck home. I dug it out of storage a few years ago and began this process, so follow along as I make mistakes and learn a thing or two about building your own expansion chamber!

Please note, this is NOT the only way to do this. I think there is an easier way- done by cutting out two sheets in the correct shape, welding the edges, and the pumping ultra high pressure water in to "expand" the pipe, but I didn't have the tools at the time to do it like that.

This is just how I did it Did you use this instructable in your classroom? Add a Teacher Note to share how you incorporated it into your lesson. This is NOT an easy quick project. It requires a lot of big, expensive tools. I'm lucky enough to have access to a shop that has everything I needed. There are alternate ways to make pipes, which I will discuss at the end of this instructable.Home Contact Us About Us. At Cone Engineering we specialize in motorcycle exhaust componentsnot finished exhaust systems for a particular year or brand.

The following pages feature a selection of our most popular exhaust components generally used in motorcycle applications, cone exhaust stuff will provide you with the right specification.

There you will find a complete listing of all our exhaust components. Our purpose is to be a source for fabricators, providing products that help them create something unique and different. What everyone has in common is the need for high-quality components to make their task easier!

And our components know no boundaries! They serve every portion of the market, from the resurrection of bikes years old to current era road racers; vintage moto to dirt tracker; a stripped down rat-bike bought at impound to high-buck full-custom one-of-a-kind builds — beauty is in the eye of the builder!

But you name it; our components fill the bill! What do you do? Well after you are done crying, man up. Then order some mandrel bends in stainless steel or mild steel and build your own brand new header!

And the best part is you can usually design your new header even better than the factory original! Maybe you could even build that ultra rare Twingle Scrambler exhaust that you once saw! From over different collector dimensions, configurations and materials in stock we have narrowed down the options a little to those most commonly used in motorcycle designs.

For more choices try the main collectors tab from the home page. We now offer several choices of pre-fabricated slip-on mufflers in both traditional and more modern styles. Instead of running a bare header try one of these megas to give a finished look and better sound to your bike. How about a few final choices? And last but not least, is a flat out mild steel max diameter race muffler.

A unique twist is the conical interior that lets you choose to run it either as a megaphone that increases from a 2. And most importantly, every muffler we make is based on our over 40 years of experience in building products for the motorcycle aftermarket exhaust industry! With over bare cones in stock to choose from, and hundreds of internal muffler component internals you have to be able to find something to stimulate you! And remember that our components are very flexible, you can often manipulate our basic parts to give many more options - cones cut in half become heat shields, the same with collectors, louver cores can become exhaust tips - the only limit is your imagination!

Exhaust Accessories. Along with the main components you may also need clamps, spring tabs, mounting tabs, heat shield tabs or other items. You can also find these listed on the link below. How to place an order.


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