I am an avid jet skier and there is a product on the market that really intrigues me http://www.atlanticjetsport.com/index.php?l=product_detail&p=456
This carbon fiber exhaust chamber is very interesting. I am wondering what kind of tooling is used to make it. It must be a two part mold where the composite is laid inside and then pressed against the mild using some type of balloon? I’m probably way off but curious to hear from those who may actually know
yes, more than likely bladder molding.
Make sure you use a very high temp epoxy resin, and that the insulation in the exhaust chamber is very, very, very well fitted. The gasses of a hot exhaust can easily evaporate the epoxy resin.
very nice and interesting…
what kind of resind should be used?
I have ruetapox VE 4434 like high temperature resin…
http://www.g-angeloni.com/pdf/162.pdf
it’s good untill 180/200 °C, but for an exhaust 200°C there aren’t many.
Few years ago I saw on a magazine a car exhaust made with carbon fibre, but I don’t know what kind of resin is
It’s a part that can be made with a simple vacuum bag. For non prepreg high temperature applications I use the Axson 2090 resin. 200° C resistant.
So they are using carbon sleeve I assume?
No. just fabric.
I know I’m resurrecting an old thread, but can any shed some more light on how a chamber like this is made?
Definitely split mold !!
Using vac bagging, it can be done like this (although I had an open end on this part, could easily have been closed
http://www.belfastmetcomposites.com/wp-content/uploads/2013/12/Internal-Bagging-Techniques.pptx
i want to test this material for a long time now. It is a damn cheap matrix that holds up to 1000ºc without any fumes. Perfect for exhaust chambers and firewall protection layer. Imagine it ends up being a much lighter exhaust than stainless steel exhaust. maybe it could even be used for engine colectors.
try this. ideal for exhaust and firewall protection up to 1000 c without fumes
Sie übersetzen das? Looks like cement. Wonder how durable it is though, but if you use it on the inside, and carbon tube on the outside…might work.
Well as you see in the pic it is flexibel. The brochure states it is vibration resistant. Maybe some ceramic stuff. They propose it also with the outside face as an epoxy laminate. 600ºc longterm exposure resitant. 50-100mpa flexure strength. 3kgm2 square meter with two layers of basalt fabric.
Does anyone have any documentation or videos on bladder molding? I’ve seen a couple of RC plane builders but not much else.
I’m curious why some people recommend a party balloon or latex balloon, and others recommend custom shaped balloons made from a soldering iron and hefty bags. Not sure what the effective differences are.
Just on the surface of the concept, one would logically deduce that a custom shaped bladder would more properly exert pressure inside the mold to make sure there are no voids, or places where the fabric follows the round curve of the balloon as opposed to the shape desired.
I just kinda figured that a latex party balloon would be pretty impressive for how it would contour inside a closed part.
But maybe you’re right and it’s not about JUST getting contact but getting EQUAL contact/pressure?
lol… 
I’d make a split mold and use a high temp epoxy.
Bond together and you’re golden.
If money isn’t an object, I’d be looking to use prepreg and a heat cured product.