ABSTRACT:- This study explores the design and performance evaluation of a Portable Motorcycle Vulcanizing Tool utilizing exhaust manifold heat for vulcanizing rubber gum. The tool aims to address common flat tire issues for motorcyclists, particularly in remote areas, by offering a portable, eco-friendly alternative to traditional vulcanizing methods. Using computer-aided simulations, the study analyzed the thermal performance of three materials—Carbon Steel, Aluminum Alloy, and Copper—under varying exhaust manifold temperatures of 60°C, 120°C, 180°C, and 240°C. Results revealed that Aluminum Alloy and Copper efficiently achieved the desired vulcanizing temperature of 60°C in less than 3 minutes, with Copper demonstrating the fastest response at high thermal loads. Carbon Steel, while durable and economical, required longer times, limiting its feasibility in low-temperature scenarios.The findings suggest that Aluminum Alloy offers an optimal balance between cost and performance, making it the most practical choice for the tool’s construction. The study highlights the potential of utilizing waste heat from exhaust manifolds as a sustainable energy source for tire repairs. The tool’s design and thermal response fulfill the objectives of efficiency, portability, and environmental sustainability. Future improvements could focus on experimental validation, alternative material exploration, and cost analysis to enhance practical applications. This innovative approach provides a significant contribution to accessible and resource-efficient tire maintenance solutions, particularly in areas where conventional vulcanizing methods are unavailable.

Keywords:- Portable vulcanizing tool, Exhaust manifold heat, Motorcycle tire repair, Thermal analysis, Aluminum alloy, Copper conductivity, Sustainable energy utilization, Eco-friendly vulcanization, Waste heat recovery, Flat tire maintenance