wtf is "07.v.2.0.A.p.CF"?

Well let's break down the code...
07.v.2.0...07/08 Pinebox Exhaust
A.............Outer Tube orientation
p.............Prototype
CF...........Carbon Fiber



That's right! I've been working on finding or building carbon fiber outer tubes for the exhausts. I can not find anyone to make then to the dimensions I want. So, I have to build them.
Here are a few details...
-These tubes are 100% carbon fiber! 100% built in house!
-They are (2) layers of 2x2 twill fabric and clear coated for UV protection.
-There is a noticeable weight reduction in the exhaust. I don't have a good scale to get the exact difference.
-I found that I can get 50% carbon fiber / 50% fiberglass fabric. That doesn't sound like much, but the fiberglass can be colored! I have a sample of a color close to the Kawi green!

More details coming soon!!!



The exhaust has been installed on a local rider's bike. He has agreed to do the testing for me. I need to know if the carbon fiber, resin and clear coat I used will hold up in this case. If all goes well, then more details will be released!

I will update this thread as req'd during the testing.

Test/inspection visit two (after ~250 miles from install)....check and in the books!

Disassembled the exhaust to inspect it inside and out.
Everything looks very good. The tubes seem to be doing just fine, however, the clear coat is having issues.

Few other notes:
-I was able to pick up a temperature gun so I could check the temps to know what they are. After riding it looks like they range anywhere from ~200*F at the tip to ~150*F.
-The left tube showed some bad signs of yellowing. The right tube wasn't as bad.
-The inside of the tubes are OK.
-The yellowing was only the last few inches of the tip, past the end ring. I attempted to sand away the clear coat to see check the condition of the resin. I wanted to know if just the clear had yellowed (or burned). I was able to get thru some of the clear in some areas. The resin looks just fine!! So much for that clear coat! I'll have to find something different.
I left the tubes with a dull finish for now. I want to see what the resin will do without a clear on it.

I found some new resin and it's on order!

I think I'll be looking into some sort of tip inside the tip idea. Not quite sure how it's going to work out. But it would add a bit of a heat shield to the carbon tube. There would be a small air gap between this new tip and the carbon tube. This would keep the majority of the heat away from the resin and carbon tube and help keep the resin nice and clear and looking good.

Possibly something like this.....




More coming soon!!

Seems like your talking to yourself here so I'll accompany you. (so you don't look like a crazy )

I think I've got the details worked for this be applied to the 03.v.x.x exhaust. But nothing much more than that.
If the 07 is burning, then the 03 would be worse, it's closer the to heat/engine. Let's see how the new resin and tip work out.


But, custom one-off's aren't out of the question tho.

From what I can find, they don't use it like I am. They only make the can section from CF, not the tip itself. The exhaust gases don't flow thru the CF section without something between the CF and exhaust gases, like it does on mine. Maybe I need to really look into revising my idea. But I'm gonna test one more set of tubes before going to something different.

Any update here Dave? Im intrested in your progress with these carbon pieces.

OK, finally got schedules worked out with my test rider. We got the new tubes and tip inserts installed last night....



I'm keeping my fingers crossed that between the new resin and tip inserts the CF tubes will be OK.

These are lookin SICK

would of got these if you had them before... its gonna be hard not to buy another set >.<

Got a look at the tubes yesterday. They are doing great! It looks like the combination of the new resin and tip inserts are making all the difference!!