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Discussion Starter #1 (Edited)
I've been running a 2bular header which I wrapped with DEI Titanium wrap. It's supposed to be good quality stuff, but mine cooked off and fell apart in less than a year. I decided to make my own out of better quality materials.

Here's the result:

IMAG0361.jpg

It is made in three pieces - top, bottom, and elbow. The fit is intentionally a bit loose, as the idea is to manage the heat, not retain all the heat inside the header, in which case most of the heat would make it to the exhaust and melt the packing. The seams allow some of the heat to dissipate, and the blanket also absorbs some heat. If I need to retain more heat, I can add more eyelets and tighten up the fit. The opening at the elbow is for the wideband sensor.

So far, the fit seems to be pretty good for heat management. After a track session, the shield itself got hot, but was still almost cool enough to touch briefly. The floor and forward wall of the trunk area were just warm; before they had been too hot to touch.

Each part is two layers of 18 oz Mil-Spec silica fabric which is rated for 2100F service, melting point 3000F. The filling is two 1/2" layers of ceramic blanket rated at 2400F. It is sewn with Kevlar; that's the weak link with a service rating of 570F. If the Kevlar starts burning out, I'll sew over it with Inconel thread if I can find some, or unravel some of the silica cloth and use that. The eyelets and zipties are stainless steel.
 

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Discussion Starter #3
I started with descriptions of turbo blankets. There are plenty of online vendors of various silica fabrics. I contacted a couple of vendors for their recommendation for this application. There are waterproof versions, but they are quite pricey.

I had the ceramic-fiber insulation on hand, which I've been using instead of fiberglass as an exhaust packing. It is used as insulation in kilns and forges, also available online.
 

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** The Enforcer **
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I didn't know there was such a thing as Inconel thread. I have an Inconel/Titanium exhaust on my ZX-10R.



San
 

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It looks good bro! I went with Moroso wrap, DEI is cheap **** that autozone sells. Let us know how it works out for you in durability please!
 

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Don't rule out stitching with nomex thread, or 32 gauge stainless steel wire.
 

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Hmmm...

Now I doubt myself ! I ceramic coated the header and then put another layer of the fiberglass cloth on the underside of the clam ( where heat shielding is already )


I also ceramic coated the decat and wrapped the ubend and decat.

I even wrapped the heat shield around the motor mount. I have zero heat on my clams. ( maybe a little where the ubend is) but not to hot to touch.

It seems to all do it's job, but then again I have never tracked my machine so maybe the heat load is just not that high.

Oh yeah ! nice work man. I might just do something similar for giggles when I have my clam off again. peacb
 

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Discussion Starter #8 (Edited)
DEI is cheap **** that autozone sells. Let us know how it works out for you in durability please!
Yeah, I found that out the hard way. I'll post a wear and tear update when I get some miles on it...

Don't rule out stitching with nomex thread, or 32 gauge stainless steel wire.
Nomex and Kevlar have the same temp specs, similar price; I went with Kevlar simply because I could buy it in a smaller quantity.

I thought about stainless wire, but I'd have to hand-sew it (same for Inconel, I'm guessing). I was able to run the Kevlar in a sewing machine.

I also ceramic coated the decat and wrapped the ubend and decat.
I forgot to mention, I'm running a 2bular silenced decat with exterior ceramic coating.
 

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All the wraps I've seen, Ti, Lava, glass, etc have service temps of 1200 and can deal with short burst of 1800... so that car cruises down the street with 1200-1400... and run 1600 at full song... No wrap will last long... The blankets and better yet, aluminum metal shielding, is about the only way you're going to get real shielding. It needs the ~2000 sustained service temp ratings... The coatings-- well, they look pretty :)

-Phil
 
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