amandeepkamboj19

It all started 3 years back when i was in my 2nd year of engineering.
The study of engineering was not sufficient for fulfilling my passion for machines especially engines, so I decided to go one step ahead and building my own engine, I went to a engine repair workshop and started working there part time.
Every time I dismantle the engine I learned something new, but still my hunger was not satisfied and I thought of going beyond this wanted to construct something of my own so the hunt started and I started converting my Thuderbird engine and transformed it into 476cc chain drive engine with hydraulic lifters but it was not efficient rather it was a failure, the level of machining of component was not up to the mark and due to leakages it lifelong only one month.
At that time was not left with money for doing further R&D on that engine. So I started reading about engines extensively and I got to know that exhaust is the very first thing to modify in order to enhance performance, so I set target of constructing an exhaust, but this time I don’t wanted to fail, so before I start building anything I started reading about exhaust how they work how they increase performance, I went to many places and took measurements of aftermarket exhausts and concluded that all these exhaust were free flow then what’s the difference in 5000 Rs exhaust and cheap 800 Rs exhaust, technically there was no difference none of them were designed considering one motorcycle in mind, all of them were universal, people in market were selling them saying performance exhaust without even knowing what will be the result if they put it on 150 cc or 220cc bike, same exhaust for every bike irrespective of cc of engine rpm and most important what consumer want whether he wants great acceleration or top speed, because while designing an exhaust designer can choose only one out of these two or he can optimize it to get a combination of both. I read in many articles that no exhaust is best exhaust because it will offer zero back pressure OK if we do not require back pressure then why performance exhaust manufacturers are making their product, confused confused confused I went to my friend, got his pulsar 150 removed its exhaust and when on national highway hmm what do you think performance would have increased??? The answer in no. No acceleration, any torque and top speed drop dead.No back pressure but still any jump in performance, now next design parameters for exhaust was scavenging. When exhaust gases flow through pipe they cool down and there density increases and due to this they slow down producing back pressure. Solution for this was to use variable diameter pipe with expanding diameter. So I constructed variable diameter bend pipe for pulsar 150. Again took it to national highway. Guess about performance... acceleration better then stock but top speed slight decrease and above 6k rpm decrease in acceleration. Again back to books what was wrong, and answer was over scavenging. I increased the velocity of air so high that it was taking the fresh charge from engine combustion chamber during valve overlap. (all this process took me 2 years to complete, as some of the fellow xbhpian would know that I was always looking for handmade exhaust, and some for my write ups in UT thread about exhaust).

And then was the turning point I got placed in ISGEC R&D dept. I relocated to yamunanagar (this is where my company is) and with my friend (who was also placed with me in same dept) together we further enhanced this exhaust project and finally made a perfect exhaust system. The exhaust sounds ultimate, never heard such a bass form a single cylinder engine, acceleration ultimate, top speed no change (we designed it for acceleration).
Now all for you will be thinking why I am writing this,
This was my dream to create something which actually works, and now when we (me and my friend) have created something we want all to taste it. So we decided to start production of this exhaust system but before this I wants feedback from all of you, Should we start the production of this exhaust? Is there a demand in market because setting a plant takes hell lot of money? Should we go ahead????
Currently we have designed exhaust for 150cc pulsar. And we can design for other bikes also.
Guys please genuine suggestion.
Thank you
PS: Few pics of prototype and final product under polishing(its me polishing dirty jobs).

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Sunny

Topic Approved

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satyenpoojary

A little bit of formatting would help!
I got lost in some text and couldnt figure where I was again!

Try scouting for a simulator, that could save some time!

PS: Best of luck!

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amandeepkamboj19

@ sunny thanks for approval.

This is the first finished piece i have created

Guys i seriously need your inputs.

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freekoo

Yes the demand is there. More and more people(thats me including) are demanding performance exhaust for their bikes to make them go as fast as possible. However clever marketing will be required to sell these exhaust as there are quiet a lot of established players KRP, Automech, Proton.......etc. If right pricing and clever & attractive designs with high tech materials is what you guys got, then go ahead. Let you guys know that i own a FZ16 and am looking for a exhaust system that is short and stubby.

arunmhetre2290

This is a exhaust that I have built for my friend, its polished stainless steel not chrome.

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amandeepkamboj19

looks good
But buildining exhaust for market require lot more things. We have to make flange and clamps and also the head connection.
Is the bending done on pipe bending machine?

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freekoo

Ya great job.......Atul told me about. I was gonna have him built one for me but then i had an accident and he went off to banglore.

arunmhetre2290

The sections have been manually welded by hand and it has a laser cut SS flange it’s a custom built exhaust it has a higher duration camshaft and a bigger carburetor.

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amandeepkamboj19

I have tried making exhaust by this process but it is very expensive, no doubt pipe bending machine is expensive but its worth,
I am planning to buy a second hand CNC pipe bending machine.
Tomorrow i will post some pics of final product.

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