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Thread: Weekend Project - High Performance Free Flow Exhaust for Yamaha FZ16.

  1. #1
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    Question NEED HELP - Weekend Project - High Performance Free Flow Exhaust for Yamaha FZ16.

    Hi All,

    This is my First post in this forum.

    Before I Ask my Question here is a disclaimer -
    I am not a professional CAD or Mechanical Engineer to know much about this.
    My Question below might be stupid to some of the experts but please do reply after a good Laugh .
    Also, All information I have is from the internet and have NO practical knowledge.

    Here we go then.
    I am currently working on building a High Performance Free Flow Exhaust for my Bike (Yamaha FZ16).
    Attached is the CAD design I made for the Exhaust (I am not a professional CAD designer but recently started it as a Hobby - by the way this is my first CAD Drawing).

    I was looking in to Details about how to make a FFE.
    I got a formula to develop a FFE.

    Here is the link to Document which gives details on how to calculate the Diameter/Length of the pipe.
    http://www.bgideas.demon.co.uk/tmanual/Tm_Ch4.pdf

    Using the above formula I get the Diameter, Length of the header pipe, secondary cone etc.
    When I calculate the formula I got Diameter of the Primary Pipe around 30mm.
    I took 35mm as I will have bend just after the Gases Come out of the Exhaust Port. (Bend After 60mm from the Exhaust Port - Please refer Images Attached)

    Figure : All Dimensions


    Primary Pipe - Measurements (Please refer Images for this)

    From my mock up CAD design I have taken the Main Pipe (From Exhaust Port till secondary pipe) Diameter as 35mm and length of which is around 650mm (65cms).
    Secondary Pipe Diameter I have taken as 45mm at the Expanded area (cone moves from 35mm dia to 45mm dia in about 100mm length).
    For the next 200-250mm I have the same Diameter of 45mm till the muffler. I have designed a slip-on muffler which gets connected to the this pipe (you can see in the CAD drawing).

    Figure : Without Muffler


    Figure : 3D View.


    Muffler Design - Measurements ( Measurements are taken looking at the Stock Muffler on the bike - Have increased about 10% as of the stock Muffler)
    For the Muffler I have taken 350mm length, 100mm diameter and
    Exhaust output diameter without DB Killer will be 60mm (double the Exhaust Port). (ON Stock Muffler this is 20mm)
    With DB Killer Exhaust output diameter will be 30mm (same as Exhaust Port). (Design - UNDER PROCESS)

    Figure : Muffler - Without DB Killer


    ALL THE ABOVE DIAMETER INFORMATION IS INTERNAL DIAMETER.


    Question: Can someone please verify if the measurement are correct or it needs few more tweaking to get desired High Performance.
    Question : Also, If someone can tell me where I can get this Exhaust Done in Bangalore.

    Bike Information:
    Displacement: 153cc
    Engine: 153cc, 4-stroke
    Maximum Power: 14 Bhp @ 7500 rpm
    Maximum Torque: 14 Nm @ 6000 rpm
    Gears: 5 Manual
    Clutch: Constant Wet Multi Plate
    Bore: 58
    Stroke: 57.9
    No. of Cylinders: 1
    Valve Per Cylinder: 2
    Chassis Type: Diamond
    Cooling Type: Air Cooling

    Awaiting your Responses.

    Thanks.
    Last edited by zubair.ahmed; 04-07-2012 at 01:21 PM. Reason: Updated Title - Added help Question

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    Super Moderator sunilg's Avatar
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    DIY thread approved.

    all the best for your project.
    (Been There Done That) x 3.25

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    Rusted asif's Avatar
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    Two options:
    Compare how close is your requirements with that of Race Concepts FFE, suggest you see the FZ16 ownership experience thread for more information.
    OR
    There was one guy in Vivek Nagar,Ejipura who makes chambers and FFE as per requirements. Don't remember the exact name and location as it was a while back had seen his workshop. I hope hes still available and will be able to help you.
    [SIGPIC][/SIGPIC]

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    Rusted princesirohi's Avatar
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    good effort, but why don't you buy from joel @ race concepts.

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    Smile Thanks Sunil

    I am a couple of queries.
    Can anyone help me with this.

    1. I want to know if my calculation are correct or need some more tweaking to get desired High Performance.
    2. Also, If someone can tell me where I can get this Exhaust Done in Bangalore.

    Thanks,
    Zubair

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    Addicted atulgupta230489's Avatar
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    Thumbs up

    that's really cool buddyx:-)
    even I've been thinking of a similar project.

    all the best man:-)

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    Rusted Hackdrag's Avatar
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    CAD drawing look quiet professional.
    One suggestion don't make your exhaust make much sound.
    Cops get attracted to it.

    Thanks for sharing the literature about Exhaust
    Helmets On +
    High-Beams Off And
    Only Headphones I need is my Exhaust!!

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    Rookie Disorder's Avatar
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    Default Re: NEED HELP - Weekend Project - High Performance Free Flow Exhaust for Yamaha FZ16.

    Did you complete the project??

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