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Lambda & Thermo Bosses As we have a large machining department, we are able to offer the highest quality cast and machined lambda bosses. ​ We stock a selection of cast and machined flanged Lambda / O2 bosses in inconel 625 and stainless steel 316 Because of the weld on fitment and the special flanged shape, this boss is highly durable and reliable. ​ GoodFabs also designs and manufactures a number of specialist component parts, such as O2 bungs and clamps that are regularly used with high performance race exhaust systems. ​ Contact us today to find out more. GoodFabs-Lambda-Thermo-bosses With a threaded insert these fit most lambda sensors GoodFabs-Lambda-Thermo-bosses GoodFabs can offer completely machined round bosses in Inconel or Stainless Steel GoodFabs-Lambda-Thermo-bosses GoodFabs Lambda bosses come with a saddle to create the perfect weld onto the tube. GoodFabs-Lambda-Thermo-bosses GoodFabs's smaller thermo bosses are a perfect match of every thermocouple. GoodFabs-Lambda-Thermo-bosses The machined bosses GoodFabs offers can be sculpted to suit the tube diameter perfectly GoodFabs-Lambda-Thermo-bosses GoodFabs's thermo bosses have a similar saddle as the lambda bosses.

Additive Manufacturing GoodFabs can offer designed and manufactured exhaust systems integrating additive manufacturing (otherwise known as direct metal laser sintering or DMLS) components in a wide range of metals, including lightweight titanium alloys, stainless steels to very high temperature and corrosion resistant nickel alloys such as inconel, all with the highest level of accuracy possible. DMLS is also referred to as 3D printing using metals. The 3D printing industry is also known as additive manufacturing. DMLS technology is widely used throughout a development phase of the exhaust systems and increasingly in race parts themselves. Where conventional casting methods often require an investment in tooling, this process allows us to make small batches - or even one-off different components - without the need of any tooling investments. In laser sintering technology, the components are built layer by layer using powdered metal, only sintering the actual geometry and support structures needed, virtually eliminating any waste materials. Both the internal and external surfaces are built simultaneously, leading to a high level of accuracy and virtually no warping. DMLS can not only provide the possibility to create very complex shapes, which would be very hard to cast using conventional methods, but can also integrate certain sensor bosses or other special features without any extra welding or assembly operations. GoodFabs works with several DMLS companies located around Europe and has a good knowledge of who does what best. We can also advise on when and where to use DMLS parts, how they might be joined to fabricated, machined or cast components and the welding techniques most likely to give a good result. Our in-house machining department has all the latest equipment and experience in post-machining laser sintered components which allow us to create any geometry and machine the parts with sealing faces, bolt threads to allow the sintered parts to be fully functional parts without any welding operations. GET IN TOUCH

TUBE FORMING TUBE BENDING PRESS FORMING BEND REQUEST FORM Tube Forming & Bending 90% of the exhaust systems fabricated by GoodFabs start with a piece of flat metal sheet rather than ready-made tube. As inconel, titanium and 321 stainless tube is not available at short notice, or in small quantities, it is more practical to form and bend sheet metal from scratch. We stock 304 stainless steel and aluminium tube in various diameters and wall thicknesses. ​ Having worked with Formula 1 design engineers for over 40 years, GoodFabs has built up a large supply of mandrel bend tooling to meet their requirements for multiple diameters, wall thicknesses and centre lines. Although most of our tube forming, bending and pressing is for our own race exhaust programmes, we do make custom made tube, bends and pressings for engine builders, motorsport teams and custom exhaust fabricators, including our competitors. ​ Download our tooling charts or visit our individual Tube Forming , Tube Bending and Press Forming pages for more information and photos. ​ You can also visit our Online Shop . ​ Please note that all our bends are produced with a minimum clamp and are supplied untrimmed. If a specific clamp and tail length is required or you would like us to trim your bends to a specific length, please state this on your enquiry. VISIT ONLINE SHOP Mandrel Bend Tooling Charts TOOLING CHARTS

Exhaust Heat Shield Insulation GoodFabs fabricates and installs the world’s best exhaust insulation for race teams, engine builders and supercar constructors. Modern exhaust systems - particularly those used by turbo-charged engines - reach very high temperatures, so there is often a requirement to add a layer of thin metal foil enclosing a layer of microthermal material. The purpose of the insulation is two-fold: to keep the heat inside the exhaust system to help the gases exit faster and to protect components and bodywork in close proximity to the manifold, turbo, secondaries and tailpipe. Shop Data Sheets ​ Microporous Insulation Material ​ GRADE 1000R 1000R Min-K® Flexible Superwool® Blanket MICROTHERM® QUILTED Needlemat Adhesive Tape PPI 8415 PPI 8415-R Heat Shielding at GoodFabs Heat Shielding at GoodFabs Heat Shielding at GoodFabs Heat Shielding at GoodFabs Heat Shielding at GoodFabs Specialised equipment is used for the heat shielding process Heat Shielding at GoodFabs Microtherm material is cut to patterns and glued prior to enclosure Thermal insulation, or heat shielding as it is also known, is often a more expensive and intricate process than assembling the exhaust components themselves. The skills and technology required to cut, press and weld the thin (<0.15mm) metal foil are not commonplace and are only known to a few select companies around the world. Sourcing the materials used in heat shielding is not straight forward as they are mainly used in the aerospace rather than the automotive or motorsport industry. Heat shielding should not be confused with regular exhaust wrap or lagging, which attaches a layer of metal or tape directly to the pipework. Heat shielding carried out by GoodFabs always involves a separate layer of microthermal or microporous material between 3 and 12mm thick, which is encapsulated by a fully welded covering of dimpled 0.1mm thick stainless steel or inconel foil. This shield is then welded directly onto the exhaust system (integral) or pressed into a special shape (clam shell) that allows it to clip over the system and fit snugly around it. Example of a non-insulated tail-pipe burning race car bodywork (seen within red circle) An assortment of dimpled foil pressings 3D printed jigs are often used to ensure that the integral heat shielding fits within the packaging Clam shell heat shields with clips designed to fit around repackable mufflers Heat shields Heat shields When should you use heat-shielding? Using an insulated heat shield around the exhaust system or the turbo can often help to increase the power output of engines with operating temperatures exceeding 800 degrees centigrade (around 1,500 degrees Fahrenheit) while limiting the thermal exposure of structural components and reducing thermal fatigue (in IndyCar, NASCAR, Rally, etc) just as a ceramic thermal barrier coating does, but with far better effect. By cladding the exhaust pipes with thermal insulation, the outer surface temperatures drop significantly and contain the heat energy within the exhaust system.​ What is integral insulation? With the turbo having been re-introduced to Formula 1, unique exhaust heat management skills are needed to create heat shields which follow the exhaust contours perfectly, even with very complex geometry. Each part is individually wrapped with insulation matting - microporous or silicate fibre are the most popular forms - followed by spot welding a dimpled stainless steel, inconel or titanium outer shell. Custom-made press tools are manufactured in-house from CAD drawings to ensure that the shells are moulded to fit perfectly over the exhaust system. ​ What is clam-shell or clip-on insulation? For exhaust systems that have more room in the engine bay or undercar area and are likely to be re-used or regularly removed, the clam shell option is sometimes preferred. This form of heat shielding fits around the exhaust system and follows its contours without being welded to the pipes themselves. Clam shells with clips or springs make it easier to remove the outer cladding which allows mechanics to perform non-destructive testing and early crack detection on the used exhaust pipes. Clip on insulation features a dual layer of foil enclosing matting between layers so adds an additional layer of heat-shielding compared to integral insulation. Should I use integral or clam shell heat-shielding? Integral or integrated heat shields are spot welded onto the exhaust system while the pressed clam shell heat shield is held together by clips or springs. Your choice of type of heat shielding will depend on how much space you have and whether you are likely to work on or test exhaust systems for damage after they have been run. GET IN TOUCH

Heritage Exhaust Systems There are many historic racing cars that still require exhaust systems or exhaust parts that can only be replicated based on the originals. In the case of historic F1 cars, we may have made the original systems back in the 80s or 90s or we may need to reverse engineer and fabricate from scratch, using the techniques and welding methods that were used at the time.​ We retain mandrel bend tooling used for F1 race systems over the past 35 years and also have a stock of parts, such as flanges, that were made or free-issued as original parts.​ We have created a booklet entitled GoodFabs: Our Motorsport Heritage . This covers the exhausts we have made since 1983, including Ayrton Senna's Toleman to Force India's recent titanium tailpipe.​ F1 V8 inconel manifold F1 HRT 2012 manifold Inconel heritage exhaust Glowing orange inconel exhaust

SHOT PEENING HEAT TREATMENT Finishing The welding process when fabricating exhaust parts induces some residual tensile stresses in the joints. These tensile stresses act to stretch or pull apart the material surface which might initiate a crack when there are enough load cycles. To improve the life of these welded metal fabrications, the residual stress levels in the materials need to be modified. This can be done using either a shot peening process or a heat treatment .​ We work closely with different companies to make sure that these processes are coordinated at the right time to ensure all delivery deadlines are met. Image courtesy of Tamworth Heat Treament

TUBE FORMING TUBE BENDING PRESS FORMING BEND REQUEST FORM Tube Forming As GoodFabs works mainly with exotic metals, such as inconel and titanium, most of the sizes of the tubes we use to make exhaust manifolds are not readily available. ​ All our inconel tube is made in-house from a flat sheet, giving us full control over all the aspects of production from the outer diameter to wall thickness, enabling us to create the most complex exhaust systems while optimising the gas flow to increase engine efficiency. ​ Next to our extensive machining department, we have a complete tube forming department with a large range of tooling for our press brakes, hydraulic presses and other forming equipment. ​ Tube is formed by the radius punch on the ram, incrementally advancing the flat sheets until a perfect cylinder is created. Our large tooling range in the forming department means we can form anything from cones and simple folds to complex geometries. Seam Welding When the tubes are formed, the cylinder is completed with a seam weld. This high-quality seam weld is automatically created by progressively forming the weld rather than welding the entire joint at once. ​ The two electrodes in our fully automatic seam welding equipment apply the correct pressure and electrical current needed for that specific exotic material (typically Inconel, titanium or stainless steel) to create the perfect uniform welds. This is done by pressing the semi-molten surfaces together to create a fusion bond. ​ One of the largest advantages of the seam welding process used at GoodFabs is that the seam welding joint is already forged due to the applied heat, which produces a durable weld which lasts. ​ To enquire about the cost of formed tube, please contact us specifying your location, as well as quantity, material, diameter and wall thickness required. Mandrel Bend Tooling Charts TOOLING CHARTS Handmade formed and welded tube Welding formed tube Stock formed inconel tube Checking formed tube dimensions Handmade formed and welded tubes BMW S1000RR inconel system Inconel tube GoodFabs team member forming tube Formed and welded tube in our staorage racks Formed and welded inconel and stainless steel tube

Our Workshop The GoodFabs workshop is located on the Crendon Industrial Estate in Motorsport Valley on the Buckinghamshire/ Oxfordshire border between Thame and Aylesbury. We employ 30 full-time staff working across several disciplines including design and administration, quality inspection and NDT, tube forming and pressing, tube bending, heat shielding, machining and fabrication/ welding. GoodFabs owns the largest selection of mandrel bend tooling designed to manipulate exotic metals such as Inconel and titanium outside the aerospace industry. We are specialists in working with nickel alloys and thin-walled, ultra-lightweight materials, mainly for the motorsport market, although we also supply other industries such as oil and gas, marine, defence and aerospace. We often have job vacancies, operate an active apprenticeship programme and are always interested to hear from potential candidates who feel that they have skills and qualifications that could be of use to us.

CMM INSPECTION LASER ETCHING LASER SCANNING NDT MATERIAL TRACEABILITY Quality & Inspection The ability to inspect and demonstrate that hand-fabricated parts have been manufactured to tight tolerances is key to supplying F1 engine builders and race teams. Accurate jigging, a skilled workforce, teamwork and stringent processes all contribute to creating a final product that can pass inspection and be delivered to an exacting customer, which is often a major automotive company. GoodFabs has made significant investments in equipment, software, training and people to ensure that there is minimal delay in getting a part accurately made, inspected and delivered. Accurate measurement using a CMM with the latest laser scanning ability, a fully equipped NDT line , laser etching and full material traceability processes ensure that GoodFabs can meet the demands of our customers.

V-Band Clamps Our V-Band clamps consist of multiple profiled segments spot-welded to an outer strap and can withstand up to 1,100°C (gas temperature). ​ We supply high quality V-B and c lamps in s tainless steel 316 with self-locking nuts. Male and female V-Band rings / flanges are machined in-house to suit tube diameters from 2" (50.8mm) to 4" (101.6mm) to our own design offering a gas tight seal with easy dismantling. ​ We can provide these clamp rings in stainless steel, inconel 625 and titanium.​ ​​ We sell male and female V-Band rings as sets to enable easy connection and separation of exhaust sections using V-Band clamps. BUY SETS ONLINE GoodFabs-Vband-clamps-stainless-inconel Inconel V-Band rings with clamp for the most robust connections. GoodFabs-Vband-clamps-stainless-inconel GoodFabs machines their V-band rings In-House in stainless steel, titanium and Inconel GoodFabs-Vband-clamps-stainless-inconel Machined V-Band rings to the highest standards GoodFabs-Vband-clamps-stainless-inconel Machined V-Band rings fit perfectly for the optimal exhaust flow and fitment GoodFabs-V-Band-Rings V-Band rings machined to the tightest tolerances for a perfect fit every time. Goodfabs-Lambda-Boss GoodFabs Lambda Bosses come threaded to suit every lambda sensor! This type of clamping system always requires less working space and can provide a reduction in overall weight when this is compared to the traditional bolted flange systems. In addition, the use of V-Band clamps reduces the time it takes to assemble a system in initial building programs and during service or maintenance during a racing event or dynotest. ​ ​ The GoodFabs V-Band clamps are engineered to index perfectly onto the tube. The assembly of the male and female clamps are made easier because of the bespoke engagement feature on both rings. This allows for a perfect alignment to ensure the gas dynamics are not disturbed throughout the connection. ​ The table below shows how the male and female V-Band ring part numbers match with tube outer diameters and the corresponding V-Band clamp part number. All rings can be provided in male (M) or female (F) although we suggest you purchase these per set unless the mating ring was also purchased from ourselves in the past.

Link Tabs GoodFabs can supply various high quality link tabs to suit every assembly. As decent reliable link tabs are so hard to find, we have designed our own link tabs to suit all exhaust systems. ​ These tabs are featured with a small footprint to ensure a perfect adhesion to the exhaust primaries. ​ Because an exhaust system has to deal with various temperature differences and other forces, we designed a link which allows for this. ​ Please note: our link tabs make use of an M5 bolt and self locking nut, which are not included unless specifically requested. ​ The link tabs can be used to join primaries to their merge collectors or to support features around the chassis or engine. GoodFabs - Link tags GoodFabs provides high quality link tags to ease the assembly of exhaust systems. GoodFabs - Link tags GoodFabs's link tabs are the perfect tool for reliable and easy assembly. GoodFabs-V-Band-Rings GoodFabs's V-Band clamps are machined to the tightest tolerances for that perfect fit! GoodFabs-V-Band-Clamps The V-Band clamps GoodFabs offers are easy to use and get the job done straight away! Goodfabs-Lambda-Boss The GoodFabs Lambda bosses are designed for a perfect fit. GoodFabs-Lambda-Thermo-bosses (8) The GoodFabs lambda bosses come threaded to suit every lambda sensor.

Merge Collectors Our merge collectors are designed so there is an optimal air flow and the exhaust dynamics of the exhaust system remain intact. This is achieved by the smooth angles and the internal peak on the merging points. ​ By having a robust slip joint while still maintaining a lightweight assembly, these collectors can be used to merge multiple pipes for motorsport applications using the hottest temperature range. ​ To make the assembly of the exhaust system even easier, these collectors can be provided with a bespoke tag and link assembly. This allows the system to be taken apart fully for visual inspection or the replacing of only one primary rather than the entire exhaust system. ​ Rather than welding the end of the collector to the tailpipe, a V-Band clamp assembly can be welded to this which allows an even easier assembly of the exhaust systems. ​ We can offer these collectors in various configurations, from 3-into-1 to 5-into-1 with different diameters. See our bending tooling charts for all the different pipe diameters we work with regularly. GoodFabs - Pressed inconel V8 4 into 1 F1 collecto GoodFabs's merge collectors are made to last! GoodFabs - Inconel - Pressings Pressed merge collectors can be made to suit every shape or form needed! GoodFabs-4-into-1-Collector-TIG welding The GoodFabs merge collectors are perfectly welded to the highest quality! GoodFabs-4-into-1-Collector GoodFabs merge collectores can be offered in Inconel, stainless steel or titanium. GoodFabs-Honda-F1-V8-Inconel Even the most complex exhaust systems use the GoodFabs merge collectors. GoodFabs-3D-Collector-Additive-Inconel GoodFabs can use DMLS to create merge collectors with a perfect fit.