Super Freak Exhaust Tube Crack

So some where along the line in the ownership of this freak, the carbon exhaust tube was over tightened and is now cracked in multiple spots. I’m trying to figure out the best way to go about fixing this.

My current idea is to 3D print a tube that I can wrap carbon around. This tube will be the ID of the exhaust tube on the freak. Once the epoxy cures, I can slit the carbon tube length wise and remove it from the mandrel. From there I can hopefully clean the exhaust tube the best I can and push the carbon tube I made into the exhaust tube with thickened epoxy. From there I can wrap two or so layers around the outside of the tube.
 

DylanS

Gorilla Smasher
Site Supporter
Location
Lebanon Pa
So some where along the line in the ownership of this freak, the carbon exhaust tube was over tightened and is now cracked in multiple spots. I’m trying to figure out the best way to go about fixing this.

My current idea is to 3D print a tube that I can wrap carbon around. This tube will be the ID of the exhaust tube on the freak. Once the epoxy cures, I can slit the carbon tube length wise and remove it from the mandrel. From there I can hopefully clean the exhaust tube the best I can and push the carbon tube I made into the exhaust tube with thickened epoxy. From there I can wrap two or so layers around the outside of the tube.
Not a bad idea, you could also 3d print a shell mold for the tube and use a vacuum bag to make a single solid tube to slide in instead of having to cut it long ways.
To be honest I think you’d be alright with 3 layers of 6oz 2x2 twill and no tube if the cracks are just hairline.
Me thinks that would be enough to seal her up and the inside carbon would provide enough structure for you to tighten your hose clamp. Won’t be fun getting in there though! Good luck post pics!
 
Not a bad idea, you could also 3d print a shell mold for the tube and use a vacuum bag to make a single solid tube to slide in instead of having to cut it long ways.
To be honest I think you’d be alright with 3 layers of 6oz 2x2 twill and no tube if the cracks are just hairline.
Me thinks that would be enough to seal her up and the inside carbon would provide enough structure for you to tighten your hose clamp. Won’t be fun getting in there though! Good luck post pics!
I will definitely update as I strip down the ski this fall. The tube is pretty shot. It’s for 3 very solid cracks in it and is partly collapsing
 
Could also use a thin wall ANODIZED or DIELECTRIC-PRIMED Aluminum Tubing Insert to reinforce the ID of the Stinger. Will lose some Stinger diameter. Or could bore the Stinger out some and minimize the Inside Diameter loss.

Aluminum works real well with Fiberglass. But Carbon Fiber will corrode Aluminum.

However,
"Ideally you should also use a Dielectric Primer on the
aluminum prior to bonding to prevent galvanic corrosion. This is how we make
carbon skin, aluminum honeycomb core structures. Carbon and aluminum have a
significant anodic potential and just separating them with a bonding layer
of epoxy is insufficient as the epoxy will permeate moisture, completing the
circuit so to speak. It's a battery in other words."

Use Hi-Temp Epoxy Resin.
 

Sanoman

themadnesssetsin
Site Supporter
Location
NE Tenn
FiberBlast makes carbon selves that l have used before and they work great.Check out a couple of my later builds on freaks.l believe that The Circus build should show the process.lf you have any questions pm me
 

97superjet

Site Supporter
Location
Minnesota
My superfreak had a cracked exhaust tube as well, all I did was use some chopped up carbon inside the crack, a small piece over that crack then one more larger piece over that. It's solid AF now lol
 

hornedogg79

dodgin' bass boats
Is it a straight tube or the funky double tube thing they tried? Cut the cracked portion off and shove a section of 2.25 stainless in there. Glue it in or use a short section of hose and clamps to secure it by the bulkhead. Carbon exhaust parts live a short life.
 
Is it a straight tube or the funky double tube thing they tried? Cut the cracked portion off and shove a section of 2.25 stainless in there. Glue it in or use a short section of hose and clamps to secure it by the bulkhead. Carbon exhaust parts live a short life.
The tube is up high on the firewall and bends down behind the firewall to the outlet on the back of the hull.
 
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