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[Dennis C]

It looks like the problem may be that the shield is just too close, have you tried bike clips

[papasmurf]

Dennis C, I agree. It needs a bigger gap and if at all possible not to be connected to the exhaust system.

I have some punched stainless sheet, (8mm holes) for a similar project. I am in the process of bending it into a tube, to fit over the exhaust but not be attached to it.

[Dennis C]

Pete, as you say the problem is with the kick start not allowing enough clearance, dare I say very very quietly, have you considered exhaust wrap?, oops, damn, there I said it, sorry.

[ric]

A curved piece of metal fitted between where the silencer strap bolts onto and the footrest hanger (totally isolated from the exhaust) would be another option.

[PeteF]

Dennis, "exhaust wrap" LOL. I have considered army gaiters; ex WD ones would be cotton I think and not melt.

Ric, now there's an idea. Just need to find an anchor for the front. But that should be do-able.

[jefrs]

Carbon fibre, almost a perfect insulator and practically unmeltable.

Tufnol should work, it can stand soldering temperatures briefly (higher than an exhaust), easier to get hold of than blocks of pure CF without plastics resin fillers. Tufnol has various grades from 130°C to 250°C caveat emptor.

Bluing of the pipe at the head indicates a temperature of roughly about 500°C which is running too hot but further down the pipe it is of course very much less than that, enough to burn but probably not much more than 100°C.

[jefrs]

Error correction - bluing is about 500°F (I really, really don't use Fahrenheit) fwiw soldering iron TCP bits are rated 6, 7, 8, for 600, 700 and 800°F, they still use Fahrenheit. Not that bluing is present but that is shows that the temperature further down the pipe has to be less and under soldering temperature which Tufnol will take. There are a number of high temperature plastics available, maybe a piece of old saucepan handle?

[PeteF]

Old saucepan handle! This is a quality, highly technical, top end machine - the very idea!
Thanks for the info on Tufnol anyway Jefrs.

[PeteF]

Looks like some grades of polyether ether ketone (PEEK) is even better for temperature.

[jefrs]

You could try melting a plastic saucepan handle but you don't dare try cutting up one of the wife's good ones. They're designed to use on a stove so they don't tend to melt and burn too easily.