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Kawasaki
636 Special Project
Taylormade was commissioned to produce a design for
a special twin-pipe underseat exhaust for the Kawasaki ZX-6R 636.
In the following pictures, you can see how the project was transformed
from design sketch to finished metal.
Paul Taylor comments: These images show how John and I usually work
together. He makes an initial drawing and I interpret it as best
I can, take some pictures, send them back to John who examines them
to see if I am following his design correctly. If not, he will send
new drawings or a note requesting modifications. An example of this
is the changes we made to the lower pipe run between image (too
low) and the second, which is much tighter around the footrest –
it is a purely cosmetic change from John, but improves the look
no end.
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How
The 636 Design Evolved
After
initial discussions with the customer, John Keogh produced design
sketches giving a variety of design ideas. This one featured the
twin-cans with a flowing pipe and a heat shield just below the seat.
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A second design was selected, using a tighter exhaust run, and an
extended and resited heel plate, together with an angled front edge
to the cans
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The revised design was produced in the Taylormade workshop, running
the pipework as close as possible to the swinging arm and subframe.
Note the quality of the welding on this prototype, to be hidden
by an extended heelplate in production.
The aluminum can is a tapering cone shape, not the easiest shape
to produce, but no problem for Taylormade.
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The end cans were offered up tight beneath the stock seat, to check
fit, before completion of the can endpieces. The black fibre pen lines
on the cans show how the shape would be altered in production to produce
a very different exhaust to the stock single can. |
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Final version. The completed muffler prototype is shown here, giving
a whole new character to the 636 rear end. |
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