Design of Exhaust Band Clamp

@Del:

I realize that this is a pretty basic component, but the problem is that the company wants an overhaul of the entire exhaust system and built from (literally) scratch. So I'm trying to find out the basic ways of determining the minimum weight, minimum width of the clamp, material to be used etc... which is basically a return to all my 101 classes, I guess.

How about a shopping trip to a parts dealer, then?

Maybe not what you are looking for but this is called KISS 101

I don't know that you can get much better, simpler, light weight, efficient, or economic than this.

too bad you used a pic of a u-bolt NOT a band clamp.....

The "pic" shows a U-bolt muffler clamp. NOT a U-bolt. The u-bolt is part of the clamp assembly.

sorry my syntax was shortened I meant u-bolt style not band style clamp.

We use a lot of both and they are not generally interchangeable.

I'm still trying to figure out what's left to "design" when it comes to these clamps.

Not that I'm brilliant, but I don't know if I could come up with anything original (and practical) if designing a "new' clamp.

Maybe his mentor knows this and just wants to see if he has any imagination. Apparently not, if he's coming here for help.

Oi vey! I came 'here' AFTER 2 days of trying to do things on my own. That's got to count for something, right?

Besides, my mentor doesn't know much on the subject himself (by his own confession). He's barely started working here himself.

There are several different sizes and different clamp types there are asian car types and german cars may use a different kind ,one has a non adjustable ring with a spring type hold that is difficult to get back on a hose and requires a wrench.

You could look under the hood of cars you have never driven.

One New way of making clamps that I would look at would use those winged bolt tighteners that you can turn with your thumb and forefinger .It would require going to a hardware store like Ace hardware and asking the salesman ds.(c)

Redesign the exhaust? Okay. After you take the manifold(s) out of the casting sand send them to the extrude honer for 3 or 4 passes. Immediately after the manifold install an X pipe for maximum scavenging. Once you have a line that's parallel to the ground install your Cat. Run the exhaust lines all the way to the back to minimize cabin noise. Under the trunk area you want to install a free flow low restriction muffler like a Borla. Finish with a chrome tip or two.

"...minimize cabin noise." Why would yo do that?

Lake pipes forever! And glass packs (if muffled at all).

Thinking outside the cat food box. Why not design out the clamp? Save on inventory and assembly time.
Don't solve the problem...remove it completely
Del

An excellent suggestion, but I'm afraid my mentor won't be so open to it.

Settled on IS 2062 (GR B) for the material after reading some old old books I found and settled on a slightly larger width than the usual specifications because my mentor thinks its smart after cobbling together some random equations he made up.

I need to find a "I'm not responsible to whatever happens to that vehicle" form to sign.

Thanks for your help, though!

Luckily you're only dealing with a few psi in a free flowing exhaust, so don't sweat it.

The "dont sweat it" condition comes free with the "design a clamp" directive.

I would immagine the worry shold be more Stress from Vibration and how it holds up to the environment from road conditions under the vehicle, as you say PSI would not be the issue.

Yes. You're absolutely right. Under the older designs, the clamp repeatedly failed and there was a lot of gas leakage from the exhaust. The problem of vibration can be easily solved (by my reckoning) by optimizing the material of the clamp. Mechanical resonance values were asked for and provided and that was one issue solved. Acoustic resonance, I figured, would have been taken care of by the muffler, so that shouldn't affect the clamps.

Summit Racing: www.summitracing.com

Jegs: www.jegs.com

Not advertising, just not reinventing the wheel, so to speak.

Why not do what many people in your sad situation do. Steal a design. That's probably just as ethical as asking total strangers to do your work for you.

• Exhaust Band Clamp Styles and Types - Cummins Parts and ...
• Exhaust Band Clamps
• Muffler Clamps - Exhaust Clamps & Hangers
• MagnaFlow Performance Exhaust
• JEGS Preformed Stainless Steel Exhaust Band Clamps - JEGS

Would you believe if I told you that all those nice blue links are all blacked out for me already?

I've landed up on multiple sites like those trying to figure this thing out.

It seems to be relatively simple to me. It's a learning exercise. Not a fishing expedition.

Define the problem, and solve it. This problem has been solved a thousand times already.

Bye.

Or you could design the "system" to use COTS parts - then you just order them!

Unless you give us the design parameters, your design objectives and specifications, it will be difficult to help you comprehensively, as there are so many good clamps available at present.

If we knew why existing clamps were not suitable, we would be able to be more objective with our suggestions.

Another site for you to try - these are used in Heavy Duty Diesel (HDD) and in the Aerospace industry among others.

I don't work for them ;o)

http://www.teconnex.com/1024.html

Please contact me at kjacobs@ptmcorporation.com or phone 586-725-2147 -

We are a metal stamping prototype and production company specializing in clips, fasteners, brackets, wrap clamps of all variations - we could help you out - we can help you with design or when you get a print we could help you with prototype parts and when it went to production we could also help you there as well. Thank you for your time - Kris Jacobs - PTM Corporation - www.ptmcorporation.com

Just fit it and weld it. No clamps to fall apart later.

This one time... at band clamp...

stainless steel.

Except you wanna be modern and cool, then carbon fiber.

I suspect you only jokingly suggested carbon fiber, but...

I expect a clamp made of CF would be subject to failure from the differing thermal expansion rates.

Make the whole exhaust from carbon with expansion fittings in between. modern cool.

I thought the muffler clamp had been universally perfected? (in conjunction with this)