Hey guys. Haven't posted much on here recently, but this has always been a great resource. I'm working on a build for my senior engineering project. Figured I'd post up the starts to the blog I'm writing, and update here as I go.
http://crecca.wordpress.com/
cliffs: Making a hybrid bike, posting here because it'll get interesting
just looked at the french website and had it translated with google. sweet idea, but will a supercharged single cylinder really be that much better than 2 non charged cylinders?
Neat concept. But can it do this?
http://www.youtube.com/watch?v=-cM9S2AzU28
I love how the china wiggles on the plastic that it rests on. Still cool regardless.
That depends on how you define better. Would this be better option for a high speed, long duration run? Probably not. For day to day driving? Absolutely. Imagine a Turbo that offers full boost from 0 rpm to redline, powered by regenerative braking. Essentially you're storing up wasted energy for you want to go fast, and removing the drag of a second cylinder when you don't.
Quote from: gregvhen on March 09, 2010, 09:44:36 AM
just looked at the french website and had it translated with google. sweet idea, but will a supercharged single cylinder really be that much better than 2 non charged cylinders?
senior design ftw. :icon_twisted:
hold on how long of a design process do they give you?
from what your blog is saying it looks like your doing a 2 year project in less than 2 months?
getting an EE here.
It's a two semester project. I'm about a month and a half in to the first semester. Fortunately, I have several other classes this semester with design projects that I will be using to put me ahead of the curve.
Project for machine and manufacturing design = all the machining and hardware to convert the cylinder to an air pump
Project for thermal power systems = characterizing a motor under a compressed air supply for doing fuel control later
Project for mechatronics = air tank/hybrid system controls design and programming
good luck
i hope you like machining or paying for machined parts lol
check this out for inspriation
http://thekneeslider.com/archives/2009/01/12/ducati-v-one-twin-to-supercharged-single-conversion/
looks like you will be designing a new crank and a new camshaft that opens the intake and exhaust every two piston cycles for the compressing cylinder.
sweet
Quote from: aaronjosephward on March 10, 2010, 08:55:55 AM
good luck
i hope you like machining or paying for machined parts lol
check this out for inspriation
http://thekneeslider.com/archives/2009/01/12/ducati-v-one-twin-to-supercharged-single-conversion/
looks like you will be designing a new crank and a new camshaft that opens the intake and exhaust every two piston cycles for the compressing cylinder.
sweet
I have a link to the ducati in the first or second entry in the blog. The idea here is to combine the mechanics of that set up with the hybrid system of the scuderi air gas hybrid motor.
No need to touch the crank shaft. Cams, possibly. There are 2 options I'm working through designs on for solving the compressor issue and new cams are on possibility. The issue is that no where really has the capabilities to make cams with two lobes without excessive costs. There are also a lot of issues with the ability to maintain enough duration when there are two lobes on the cam instead of one. The other option(and the option the ducati guy went with) is a new valve system using reed valves at the intake and exhaust ports. I have a reed valve in the mail to experiment with this.
Picked up the bike today. $400 for a 96 GS. Has a corbin seat, vance and hines exhaust, and clip ons.
Needs a new tire, the carbs rebuilt, new brake lever, and possibly a new battery(charging it right now to see if it needs replaced).
(http://i28.photobucket.com/albums/c217/saxman242/gs5001.jpg)
(http://i28.photobucket.com/albums/c217/saxman242/gs5002.jpg)
(http://i28.photobucket.com/albums/c217/saxman242/gs5003.jpg)
(http://i28.photobucket.com/albums/c217/saxman242/gs5004.jpg)
(http://i28.photobucket.com/albums/c217/saxman242/gs5005.jpg)
(http://i28.photobucket.com/albums/c217/saxman242/gs5006.jpg)
Got the bike running and riding around. Still needs new tires before I'll trust it for more than just circles in a parking lot though.
do some research on air powered motors, they use tiller motors, and weld onto the cam, then polish it to get compression on every stroke. may work out ok for u?
The cams can be done that way, but it seems to bring up issues regarding how much duration one can achieve, which really limits air flow into the motor, at least when converting a gas motor over.
Currently, I'm moving forward with leaving the cams stock, essentially removing the valves from one piston, and installing reed valves at the intake and exhaust ports.
I appreciate the input though, the more ideas the better.
As for the bike, it's up in the air at the moment, getting new tires tomorrow. After that, valve adjustment and rejetting the carbs. It's running super rich at the moment due to the p.o. rejetting WAY too large.
Once I get it running in good shape, off to the dyno for some baseline runs and riding around to get some fuel consumption data.
sounds like you have a long way ahead of you! we love pictures around here, and scans of dyno sheets are more prized around here than 21 yr old virgin strippers that love gs500's!
Got the bike up in the air right now. Liking this rear stand. Cost a whopping $39 at Harbor Freight.
(http://crecca.files.wordpress.com/2010/03/dsc00039.jpg)
Taking the wheels to get new tires put on them tomorrow. The rear wheel looks like this:
(http://crecca.files.wordpress.com/2010/03/dsc00040.jpg)
:sad:
Other than a few <20 mph rides around the neighborhood to make sure everything is working, I'm not about to trust that tire to go very far. How the p.o. let it get that bad is beyond me.
the chain is scarier, and oh my, riding without a rubber can be life changing ! (the shifter) ;)
Quote from: ohgood on March 14, 2010, 03:17:49 PM
the chain is scarier, and oh my, riding without a rubber can be life changing ! (the shifter) ;)
The chain is actually almost new. Had a bunch of crap on it when I got the bike, but I cleaned and lubed it and it's looking better.
Not sure why it looks so damn rusty in the pictures.
Low sided the bike today turning onto a street. Bike has been bogging, etc, and generally running like crap at low rpm. Took off from a light slowly turning, it started to bog, I gave it more gas, and it decided it was time to go... straight towards the median. I panicked, grabbed too much brake and fixated on the curb. Dropped it, landed on my foot. Bike has a few minor scuffs, no biggie. I have a knot the size of baseball on my thigh, and my foot hurts like crazy from the bike landing on it.
Wouldn't have been too bad if a cop hadn't pulled up literally 10 seconds after.
Oh well, could have been a lot worse. Was wearing full gear, ended up with one little cut on my knee. The bruises will hurt more, the bruised ego will hurt the most.
Lesson learned... not riding the bike again until I sort out the carbs and spend more time in the parking lot doing low speed maneuvers.
May have broken a bone in my foot. Awesome!
:icon_rolleyes:
Crap that sucks :( Hope you heal quickly.
This looks really interesting, I look forward to reading more about it :thumb:
I'm healing up nicely. Still have a big knot on my thigh, and my foot is quite swollen still. I'm starting to walk with less and less of a limp.
Think I avoided breaking my foot, although it wouldn't have shocked me.
Going to be doing most of the machining for the compress conversion in the next two weeks. Lots of pictures to follow.
Spent a while this weekend working on getting the garage all set up so that I could have a good designated work area. Thanks to craigslist, a new workbench has found its way to the garage for the huge price of free. Got the extra motor up on the bench with the reed valve and carbs to start getting an idea exactly where things are going to go.
(http://crecca.files.wordpress.com/2010/03/dsc00074-e1270361031839.jpg)
(http://crecca.files.wordpress.com/2010/03/dsc00064-e1270361006603.jpg)
(http://crecca.files.wordpress.com/2010/03/dsc00065-e1270360979687.jpg)
For the compressor design, reed valves are going to be used. They seem to fit perfectly on the exhaust side with how the polaris boot is designed. Almost like it was meant to be.
(http://crecca.files.wordpress.com/2010/03/dsc00066-e1270360956355.jpg)
I will have to verify on the bike for frame clearance before machining the halve housings(probably next week over spring break).
On the intake side, the valve will be replacing one of the carbs. Should fit nicely, as it's about the same size as one of the carbs.
(http://crecca.files.wordpress.com/2010/03/dsc00072-e1270360929137.jpg)
On the carb note, it looks like the left cylinder will be the one becoming the compressor, as the right carb has all the controls on it. The carbs are set up so the right one has the throttle hooked up to it, etc, and via levers and such, controls the left one. Makes it much easier to ditch the left carb than the right carb, and as the bike is pretty much symmetrical, there shouldn't be any other issues.
(http://crecca.files.wordpress.com/2010/03/dsc00073-e1270360906721.jpg)
I still haven't decided if I'm going to even stay with a carb set up, but I'll certainly plan for the option there, as doing a fuel injection system would require the same work, left or right.
To finish off the compressor, I'll need to get rid of the stock valves.
(http://crecca.files.wordpress.com/2010/03/dsc00068-e1270360880872.jpg)
I may be able to remove just the valve itself, and leave all of the springs and such in place. After taking the valve cover off the motor, the valve channels seem to be sealed up nice and tight, so it would make life really easy if the valve train would still operate with the valve itself removed.
(http://crecca.files.wordpress.com/2010/03/dsc00069-e1270360847447.jpg)
In addition to this work, I installed new tires on the bike, along with new brake pads. Now just to rejet the carbs(parts are in the mail) and it'll be ready to ride to start getting some baseline fuel economy figures.
in photo #3 on first page, it looks like the front fork is bent...
I hope that it's only light playing tricks on me!!
Bent forks are just an illusion. Who knows how long they'll staying stock anyway
Bit of an update. Finished the valve housings today. Conversion of one of the cylinders to a pump is about 90% there.
since everyone loves pictures
How the design started
(http://crecca.files.wordpress.com/2010/04/valve-housing-design.jpg)
Milled from 4"x4"x3" 6061 billets
(http://crecca.files.wordpress.com/2010/04/progress-valve-housing.jpg)
Almost finished product
(http://crecca.files.wordpress.com/2010/04/finished-valve-housing-2.jpg)
(http://crecca.files.wordpress.com/2010/04/finished-valve-housing.jpg)
Spent a while working on the bike project today. Got the new valve housings all bolted up, and the old valves removed.
I really need to do some cleaning to get all that built up gunk out of there. Any suggestions?
(http://crecca.files.wordpress.com/2010/04/dsc00158.jpg)
(http://crecca.files.wordpress.com/2010/04/dsc00161.jpg)
(http://crecca.files.wordpress.com/2010/04/dsc00160.jpg)
(http://crecca.files.wordpress.com/2010/04/dsc00164.jpg)
(http://crecca.files.wordpress.com/2010/04/dsc00162.jpg)
dude, I have no idea what you're doing but it looks cool as hell :thumb:
I love the screens from Rhino 3D
in for results... my buddy just finished his senior design at RIT and his project was pretty lame. But he is working for Intel in a month so I guess its all right, I start in the fall for ME @ RIT...
Solved the issue with the stock valves today. Replaced the valves with a bolt with o-rings on each side and a lock nut to securely hold it in place. Should seal things off nicely. Managed to clean the combustion chamber up a bit too. Lots of carb cleaner and scrubbing with a wire brush. Tomorrow I'll torque everything down, get the cams properly aligned and the motor will be ready for testing.
Everything all cleaned up
(http://crecca.files.wordpress.com/2010/05/dsc00165.jpg)
Where the valves were that needs to be sealed.
(http://crecca.files.wordpress.com/2010/05/dsc00168.jpg)
Replacement for the valves to seal everything up
(http://crecca.files.wordpress.com/2010/05/dsc00170.jpg)
Valves all sealed up
(http://crecca.files.wordpress.com/2010/05/dsc00171.jpg)
(http://crecca.files.wordpress.com/2010/05/dsc00172.jpg)
is this going to be intercooled? if not, seems it would have been simpler to have the compressed air on the carb side, to allow you to use a simple u-bend to connect the pressurized air to the carb
Quote from: jeremy_nash on May 02, 2010, 07:53:58 AM
is this going to be intercooled? if not, seems it would have been simpler to have the compressed air on the carb side, to allow you to use a simple u-bend to connect the pressurized air to the carb
Intercooled... possibly. We'll see. It will, however, have an air tank between each cylinder. That said, I suppose it wouldn't make much difference which side was the exhaust. Ultimately, it'll come down to a packaging issue once I try to fit everything on the bike. It won't be that hard to swap sides if needed.
oh, I guess a chamber to allow the air pulses to stabilise would be a good idea.
have you done any math to give you a theoretical power number?
Quote from: jeremy_nash on May 02, 2010, 11:39:29 AM
oh, I guess a chamber to allow the air pulses to stabilise would be a good idea.
have you done any math to give you a theoretical power number?
The air chamber serves a couple purposes. One is certainly to stabilize the air pulses, but the main reasoning is to allow a certain amount of controls to occur. A pressure vessel can be regulated so that boost is available on demand and can be stored for more opportune times. Essentially it's the pressure vessel and corresponding controls that separate this from being an internally supercharged system to being an actual air gas hybrid.
I have not done much in the way of calculations of expected power output, however, there's a guy in France that has done something very similar to a ducati, at least as far as the compressor design goes, and sees about 20% more hp over stock, with a much fatter torque curve.
So this motor showed up not exactly working. Wasn't really given a reason other than it doesn't work and part was broken.
Was able to salvage enough for the testing I needed, so I'm ok there, but I seem to have found part of the reason it wouldn't run before. The intake valve on the side of the motor I'm not touching is horribly out of adjustment. The valve isn't completely shutting, so during the compression stroke, all of the air is being forced back out through the intake. I'll need to pick up some new valve shims and hopefully that'll fix that issue. Otherwise, I have the motor back together and making compression. Once I get the intake valve properly shimmed, the testing can begin.
The back left valve is the one sticking open.
(http://crecca.files.wordpress.com/2010/05/dsc00180.jpg)
Starting to look like a motor again.
(http://crecca.files.wordpress.com/2010/05/dsc00185.jpg)
This is so freakin cool! Be sure to keep us posted
Will do.
Tonight's progress involved trying to get the untouched side of the motor to cooperate. Swapped in a smaller shim as I was having issues with the intake valve sealing on the side of the motor I didn't touch, and while that gave me appropriate clearance, it still wouldn't seal. I pulled the head off again, and ended up pulling the valves, swapping them for the valves I removed from the other side, lapped them, and bolted everything back together. Still isn't cooperate entirely, but got a much better seal. Also cnc'd an adapater flange that I'll be able to hook up a small air tank to for making comparison tests between air flows on both sides of the motor. No pictures today, as it pretty much looks the same as last time.
Time for a bit of theory. Ideal air flow through a reciprocating pump, in this case an engine, can be calculated based as m dot(mass air flow)=pDN/120 for a 4 stroke motor, where p is air density, D is displacement, and N is rpm. For a motor that intakes air with every rotation, instead of every other, this becomes mdot=pDN/60. Long story short, if it can be shown that the valves on the motor are opening twice as often on the compressor side as on the combustion side, the motor should flow twice as much air.
The motor was displayed yesterday to show proof of concept as an internal supercharger. For this demonstration, the starter motor was hooked up to a 12V battery and allowed to crank the motor over. Through observation, one can see that the valves are indeed operating as designed, with the compressor valves opening on every crank rotation and the untouched cylinder opening on every other. This is far from running, but shows proof of concept. The valve movement on the reed valves is a bit difficult to see, as not much air is flowing with just the starter going, but close observation makes it visible.
http://www.youtube.com/watch?v=I-aw8V151_M
In addition, I picked up an 06 GSXR-600 front suspension today that will make its way onto the bike to update the antiquated brakes and suspension. One fork is a bit bent, so I'll pull them both and take them to either have that one straightened and the other one checked, or replace them with a straight set, but will work great at updating the front end.
Here's the front end I picked up:
(http://crecca.files.wordpress.com/2010/05/dsc00191.jpg)
Been starting to work on roughing out the fuel system for the bike. Torn between developing my own fuel injection using a microprocessor board I build and using something already out there like megasquirt. If I do megasquirt, I'll probably still have to build a small microprocessor board to do all the boost controls for me, although it may have some built in PID control options I can make work. We'll see.
Torn between making my own intake manifold/throttle bodies and just stealing something off a gsxr or an r6. Running boost, I'd like to be able to run a map sensor for better tuning, but doing this on an itb set up is a bit difficult. Perhaps I'll make a small intake plenum.
Also, fuel injection means I need a tank with a fuel pump in it. I can either take a stock tank and try to find room for a fuel tank, or more likely I'll make my own tank from scratch.
This weekend I'm going to try to finalize the design for the rear sets I'll be making so I can start churning them out. Should bring in some income to help fund the project. Going to try to get the fork straightened this weekend as well and see if the front wheel I have is salvageable. Next week I'll try to finalize what I'm going to do about the fuel injection and start on the design for the tank.
This is certainly turning into one hell of a frankenbike
Yes, but one hell of a Frankenbike! Originality counts more than anything and this is completely original. Lucky you are to have the knowledge and tools to CNC parts. Makes building a lot more fun I'll bet.
So, if the proof worked, you passed the class, right? :thumb:
Quote from: O.C.D. on May 20, 2010, 07:21:43 AM
Yes, but one hell of a Frankenbike! Originality counts more than anything and this is completely original. Lucky you are to have the knowledge and tools to CNC parts. Makes building a lot more fun I'll bet.
So, if the proof worked, you passed the class, right? :thumb:
Proof worked, everyone was impressed, etc. Still have a final exam for the class tomorrow, but shouldn't be an issue.
Being able to cnc stuff certainly is nice. Also helps that I have a whole set up in my garage for vacuum infusing composite parts. The tank I make(and eventually any fairings/fenders/etc as I turn my focus towards the aesthetics) will all be carbon fiber and kevlar, as I have rolls of the stuff sitting here.
Big part of why I'm going to such great lengths is so that I can use this all on my resume and really show the skill set I posses.
Now saying you can make all those parts out of carbon really will open a can of worms around here, lol. Start designing a new chin spoiler and I am in!!!
A new chin spoiler is on the to-do list, but a bit of a lower priority at the moment.
Started doing some concept sketches for the rear sets, using an eccentric bolt for adjustment along with the normal bolt array.
(http://crecca.files.wordpress.com/2010/05/rearset.jpg)
futuristic. Ill take any of those that you decide you dont like :icon_mrgreen:. assuming you make more than one pair that is.
Nice sketch. But seems redundant to have both bolt hole array and eccentric.
Quote from: gregvhen on May 20, 2010, 08:53:02 PM
futuristic. Ill take any of those that you decide you dont like :icon_mrgreen:. assuming you make more than one pair that is.
Planning on selling 'em
Idea with putting the bolt hole array and an eccentric is that you can really fine tune things to put the pegs exactly where you want. I need to actually build a prototype and decide if it's necessary or not.
ill give you an second opinion on them if you want to know how others feel. just send me a pair when ever and ill do a reveiw :icon_mrgreen: :thumb:
Well, out of curiosity, how much adjustment would everyone like to see? Obviously not having the array would make life way easier (and everything cheaper) if that much adjustment wasn't wanted/needed.
(http://www.familyjones.org/paul/rearset.jpg)
I have been happy with these. I have had to adjust them on two occasions, and didn't feel a need for in-between adjustment. They are 6mm tapped holes on 12mm centers X and Y. That gives me 24mm adjustment forward/back, and 36mm up/down.
If you could make a set with more ground clearance relatively inexpensive I would be very interested. Dont need a ton more clearance, just like 0.5-2.0"up and 0.5-1.0"back.
Quote from: Paulcet on May 21, 2010, 10:05:17 AM
(http://www.familyjones.org/paul/rearset.jpg)
I have been happy with these. I have had to adjust them on two occasions, and didn't feel a need for in-between adjustment. They are 6mm tapped holes on 12mm centers X and Y. That gives me 24mm adjustment forward/back, and 36mm up/down.
Sounds good. What are you using for the actual peg/lever?
On an unrelated note, I won a set of gsxr 600 throttle bodies on ebay today. Fuel injection process is getting started.
Quote from: saxman on May 21, 2010, 04:23:40 PM
Sounds good. What are you using for the actual peg/lever?
They are GSXR pieces.
just curious have you gotten it to run yet?
Quote from: plurpimpin on May 21, 2010, 07:48:22 PM
just curious have you gotten it to run yet?
Far from even trying. I finished proof of concept showing that the valving changes do in fact work on my second test motor. Before trying to run the bike with the new valving and such, I want to get it running a somewhat stock configuration on fuel injection. One step at a time. If I try to add the fuel injection and the valving changes at the same time, I have to try to troubleshoot two things at once. Furthermore, having a solid fuel and ignition map to work with will make scaling up to positive pressure much easier that trying to start from scratch. My goal is to have the motor running in its new configuration by August.
finding gsxr pegs and the mounts are almost impossible, but if you can find them out there, they are outrageously priced! machine up your own modeled after woodcraft, vortex, or gillys and not rely on a "stealership" part as replacement. just make plates for all bikes, the sets will be universal minus shifter set up. You've got a business! I found a set of vortex at cycle gear for a gsxr, $385, then made my own adapted brackets. most brakes and shifters work off a spline w/ a grease groove sys, and the peg screws in or gets tapped from the rear(thats what she said). i can take off my vortex and take pics if you really taking this into marketing. might be pricy for such a select few. but hey, what is there for our beloved GS, make me a set. first dibs!
(http://i282.photobucket.com/albums/kk273/mrlopee/DSCF2740.jpg)
Quote from: lopee on May 21, 2010, 09:03:31 PM
finding gsxr pegs and the mounts are almost impossible, but if you can find them out there, they are outrageously priced! machine up your own modeled after woodcraft, vortex, or gillys and not rely on a "stealership" part as replacement. just make plates for all bikes, the sets will be universal minus shifter set up. You've got a business! I found a set of vortex at cycle gear for a gsxr, $385, then made my own adapted brackets. most brakes and shifters work off a spline w/ a grease groove sys, and the peg screws in or gets tapped from the rear(thats what she said). i can take off my vortex and take pics if you really taking this into marketing. might be pricy for such a select few. but hey, what is there for our beloved GS, make me a set. first dibs!
(http://i282.photobucket.com/albums/kk273/mrlopee/DSCF2740.jpg)
Any chance of a picture from further back? Trying to get an idea of placement of the foot pegs based on your set up.
Back on the topic of my bike, the megasquirt stuff showed up today. Have a bunch of soldering to do, but I now have an ecu for running fuel injection/controlling ignition timing.
(http://crecca.files.wordpress.com/2010/05/dsc00213.jpg)
Spent a good 6 hours with a soldering iron today, but just about finished the ecu for the bike.
Megasquirt ecu and relay board
When I started:
(http://crecca.files.wordpress.com/2010/05/dsc00214a.jpg)
finishedish:
(http://crecca.files.wordpress.com/2010/05/dsc00216a.jpg)
(http://crecca.files.wordpress.com/2010/05/dsc00217a.jpg)
few things will have to be added once I decide on some specifics of some of the sensors I'm using and make some choices about how I want to do ignition, etc, but otherwise done.
and I thought that my Mini3 Headphone amp was quite a challenge to solder :thumb:
Nice work!
Quote from: kml.krk on May 31, 2010, 12:55:31 PM
and I thought that my Mini3 Headphone amp was quite a challenge to solder :thumb:
Nice work!
The soldering wasn't too bad, other than a handful of tiny transistors. Just so much to do it took forever.
^^^^^^^^^
for me the hardest part was soldering on the sound processors. Those tiny legs are so close to each other... ;)
Quote from: kml.krk on June 01, 2010, 11:13:09 AM
^^^^^^^^^
for me the hardest part was soldering on the sound processors. Those tiny legs are so close to each other... ;)
that was the issue with the transistors. The distance between each pad was literally less than the width of a hair
damn,
i actually have an assembled relay board laying in my basement that i have no use for.
let me know if you destroy that one
wow MS v3.0! I put together an older version for a corrado a few years back. The new boards are pretty slick :thumb: the only thing I regret was making my own cable between the relay board and the MS. It took hours to solder all the wires to the pins, and turned out to be a Buddha Loves You to debug when one of the solder joints failed. In hindsight, I should have paid to buy a nicely pre-made cable! Did you make a MegaStim as well? It sure was nice to prove things on the megastim first before sticking it into the car...
Quote from: Flanders on June 01, 2010, 12:57:52 PM
wow MS v3.0! I put together an older version for a corrado a few years back. The new boards are pretty slick :thumb: the only thing I regret was making my own cable between the relay board and the MS. It took hours to solder all the wires to the pins, and turned out to be a Buddha Loves You to debug when one of the solder joints failed. In hindsight, I should have paid to buy a nicely pre-made cable! Did you make a MegaStim as well? It sure was nice to prove things on the megastim first before sticking it into the car...
Didn't buy the stim... been using a signal generator to test stuff out so far. Wonders of having access to a fully equipped shop.
I just couldn't justify the $60-70 cost for the cable between the boards
While progress continues on the fuel system (throttle bodies have shown up and I've started to modify them, etc), I tackled another little side project. Part of what I wanted to do with this bike is update it as a whole, so I've decided to replace the brakes and suspension of the bike. Silly to have a modern engine system with brakes and suspension a quarter of a century out of date. Next week, I'll be posting up about the front suspension/brakes which are being replaced with a complete front end from an 07 Suzuki gsxr 600, but for now, here's an update on the rear suspension.
Enter R6 rear shock.
(http://crecca.files.wordpress.com/2010/06/2010-06-19-12-39-56.jpg)
Bolted right up. No issues with needing to grind the swingarm or anything.
(http://crecca.files.wordpress.com/2010/06/dsc00218a.jpg)
(http://crecca.files.wordpress.com/2010/06/dsc00219a.jpg)
(http://crecca.files.wordpress.com/2010/06/dsc00220a.jpg)
Interestingly, it seems the previous owner of the bike had swapped in one of the older GSXR shocks with the remote reservoir. Anyone want it?
(http://crecca.files.wordpress.com/2010/06/dsc00221a.jpg)
in swapping from the gsxr to the r6 shock, it lowered it about 2 inches right? when I put my gsxr shock on, my bike raised 2 inches, but it dont matter, that r6 shock is hott
Quote from: jeremy_nash on June 22, 2010, 04:50:11 AM
in swapping from the gsxr to the r6 shock, it lowered it about 2 inches right? when I put my gsxr shock on, my bike raised 2 inches, but it dont matter, that r6 shock is hott
I didn't measure, but the bike does feel like I'm sitting a bit more vertically with the R6 shock than the gsxr shock, so I'd imagine the rear is a bit lower.
Quote from: saxman on June 21, 2010, 08:55:32 PM
[...]
Bolted right up. No issues with needing to grind the swingarm or anything.
I also have R6 shock, and I think that grinding of the swing arm is required.
The reason for that is that under heavy compression the coil of the spring may actually grind against swing arm.
Just to be safe I ground mine. About 3-4mm is all it takes.
KML
Quote from: kml.krk on June 22, 2010, 04:47:29 PM
Quote from: saxman on June 21, 2010, 08:55:32 PM
[...]
Bolted right up. No issues with needing to grind the swingarm or anything.
I also have R6 shock, and I think that grinding of the swing arm is required.
The reason for that is that under heavy compression the coil of the spring may actually grind against swing arm.
Just to be safe I ground mine. About 3-4mm is all it takes.
KML
Searching I've done on the matter suggests that some people have had clearance issues, some have not. I'll keep an eye on it, but seems I may have been lucky and be part of the group that's good without.
I had to grind mine a few times to clear it as well.
Been a bit busy since the last post. As promised, albeit a few days late, I've tackled the front suspension. For the front suspension, something a bit more modern was wanted. A supersport inverted fork layout was selected, for increased performance in steering and braking and for the aesthetic upgrade. From the factory, the GS500 comes with a very underwhelming front end, especially for anyone over about 140 lbs. In its stock form, an upgrade is a huge improvement, so when modifications are being done to up power output, suspension and brakes ought not be overlooked. Thanks to the wonders of craigslist, I was able to pick up a front suspension off a wrecked '06 Suzuki GSX-R600. I was told by the seller that one fork was slightly bent, but everything else was in great shape. The front wheel, however, was a total loss. I paid a great price for this condition. Unfortunately, after further inspection, this description was a bit of an understatement. The guys at G P frame in Napa, Ca did a wonderful job getting the front end all sorted out. Both forks needed lots of work, along with the upper and lower triple trees and the axle. Far from the one fork needing slight adjustment I had expected. After a hole in my wallet, I was left with a great front end to use.
Unfortunately, the front wheel that came on the front end was not salvageable, despite the efforts by G P frame. I ended up picking up a 98 GSXR 600 front wheel off ebay for a great price. About 1/4 of what an 06-07 GSXR wheel would cost. Unfortunately, these are not a direct bolt up. The brake rotors that came with the front end would not bolt up to the older gsxr wheel. Instead, I picked up a set of Hayabusa brake rotors. They bolt up the wheel, but weren't a direct fit to the brake calipers. More on that in a bit.
Now the GS500 is a much smaller, less expensive bike than the supersports, and as such have a much smaller, weaker suspension set up. The GSXR front end does not bolt up to the GS500 frame. To solve this, I went to Bob Broussard, an experienced GS500 builder who has done this front suspension swap many times. The GS500 stem was pressed out of the GS lower triple, welded to add some material, then shaped and pressed into the GSXR lower triple. This allows the lower triple to mate to the GS500 frame, however, the top GSXR triple tree needed an adapter to be made. I had to modify the frame slightly to use the GSXR ignition module, just for clearance. A new steering stop will need to be made and welded to the GS frame, however, I haven't tackled this yet. This new steering stop will also act as a point from the GSXR steering damper to bolt to.
After adapting the front suspension to the frame, attention was turned to the wheel and brake issues. The 06 GSXR axle fit the older wheel great, however the spacer used to center the wheel was too large, causing the wheel to sit off center and rub. About 5mm was removed from the surface that meets the wheel on the spacer, centering it while mounted. The brake rotors sit about 2mm further apart than the older ones, however, play in the brake calipers will easily make up for this. The calipers, however, did need to be spaced out to clear the larger 320mm diameter Hayabusa rotors over the 310mm GSXR rotors. Honda sells a caliper spacer that would have achieved this goal, however, all the local dealers were out of stock and it offered a good excuse to practice my lathe skills and save $25. I picked up some 1" diameter aluminum bar stock, and turned a set of spacers for the calipers.
The new, updated hand controls require some serious rewiring. As I am converting to fuel injection concurrently, significant wiring needs to be down there as well. As such, I removed the stock wiring harness from the bike, and used the opportunity to start cleaning things up. Some serious modifications to the frame were completed as well. As I will be running a solo seat, an abbreviated tail for aesthetic reasons, and a under bike mounted exhaust, I ground off the passenger pegs, exhaust hanger, and a section of the rear frame. Also painted the front wheel while it was without a tire. Now onto the pictures:
(http://crecca.files.wordpress.com/2010/06/dsc00225a.jpg)
Before cutting and with the stock front end.
(http://crecca.files.wordpress.com/2010/06/dsc00228a.jpg)
Stock front suspension
(http://crecca.files.wordpress.com/2010/06/dsc0239a.jpg)
Stock 1989 model year only clip on controls
(http://crecca.files.wordpress.com/2010/06/dsc00253a.jpg)
Comparison between the old and new front forks. Note that the GS stem has already been pressed into the GSXR triple tree
(http://crecca.files.wordpress.com/2010/06/dsc00257a.jpg)
With the GS stem, everything bolts up to the frame like stock
(http://crecca.files.wordpress.com/2010/06/dsc00272a.jpg)
The aluminum adapter made to fit the GSXR top triple tree and the steering lock ground down for clearance of the GSXR ignition module
(http://crecca.files.wordpress.com/2010/06/dsc00264a.jpg)
Mock up with the new controls in place, older wheel, etc
(http://crecca.files.wordpress.com/2010/07/dsc00291a.jpg)
Calipers mounted up with the 5mm spacers I made in place
(http://crecca.files.wordpress.com/2010/06/dsc00269a.jpg)
Profile with the new front end
(http://crecca.files.wordpress.com/2010/06/dsc00277a.jpg)
Stripped down, waiting to go under the knife
(http://crecca.files.wordpress.com/2010/06/dsc00280a.jpg)
Unneeded extras removed. Stock front end was put back on temporarily so I could roll the bike around prior to mounting a tire on the new wheel.
Haven't posted up in a while. Moved to a new house and in the process, misplaced my camera cord. Was hoping to wait until I had some quality photos to post, but one off my cell phone will have to do.
As part of the fuel injection system on the bike, a fuel pump is needed. Unfortunately, a gas tank for the GS500 that accepts a fuel tank does not exist. As such, I must make one. What I'm doing is taking the stock gas tank from the current generation GS500 and working off that. I stripped a tank down and used it to make fiberglass molds of the tank. From that, I've made a fiberglass replica of the tank, which is then shaped to accept the fuel tank and any other modifications I deem fit. From there, another set of molds are pulled and then the tank is finally made out of carbon fiber and kevlar.
Here is my fiberglass plug, ready to start modifying, fresh out of the fiberglass molds.
(http://crecca.files.wordpress.com/2010/10/2010-09-30-20-15-231.jpg)
OT represent
Great thread..so much work...so much heart.
Really interesting stuff. Updates.... ?
Quote from: tb0lt on October 12, 2010, 12:19:58 AM
Really interesting stuff. Updates.... ?
Still hard at work on the gas tank. I'll post up pictures of the whole process when I finish it. Probably in the next week.
Amazing stuff keep us updated!
Quote from: Paulcet on March 09, 2010, 12:03:49 PM
Neat concept. But can it do this?
http://www.youtube.com/watch?v=-cM9S2AzU28
http://www.youtube.com/watch?v=NG57XNgKPNU (http://www.youtube.com/watch?v=NG57XNgKPNU)
Watch the one in the quotes then watch this one. funny stuff.
This is an absolutely amazing build. It must be great to have all these resources and be able create anything you can imagine.
Quote from: ragecage23 on October 12, 2010, 12:33:42 PM
Quote from: Paulcet on March 09, 2010, 12:03:49 PM
Neat concept. But can it do this?
http://www.youtube.com/watch?v=-cM9S2AzU28
http://www.youtube.com/watch?v=NG57XNgKPNU (http://www.youtube.com/watch?v=NG57XNgKPNU)
Watch the one in the quotes then watch this one. funny stuff.
LMAO the rear blinker assembly looks like a set of gonads! But funny very funny! I thought they were going to pull his balls off at first ROFL..just saying
Great build. Can't wait to see it finished. Something I was thinking about is what if your next project you did like a three cylinder triumph with one acting as the compressor and the other two powering like normal.
Making progress on the gas tank. Painted blue briefly to make the shaping a bit easier. The final molds aren't too far on the horizon. Then it's cf/kevlar time. Going to leave it floating a bit so that all the hybrid components are visible on the intake side of the motor.
(http://crecca.files.wordpress.com/2010/10/p1010206trim.jpg)
(http://crecca.files.wordpress.com/2010/10/p1010210trim.jpg)
Wow..you got your hands full of dust!
Quote from: JB848 on October 12, 2010, 09:04:47 PM
Wow..you got your hands full of dust!
Now I really do. Damn stuff is everywhere.
Tank is almost ready to go though. Hopefully this weekend it'll be time to start pulling molds off of it.
Everywhere that is blue still needs to come down and be surfaced, and I've started a final skim coat. Then primer and final surfacing.
(http://crecca.files.wordpress.com/2010/10/p1010211small.jpg)
(http://crecca.files.wordpress.com/2010/10/p1010214small.jpg)
(http://crecca.files.wordpress.com/2010/10/p1010215small.jpg)
nice progress. nice neighborhood ;) is that Porsche in the background of the first pic?
Quote from: ragecage23 on October 12, 2010, 12:33:42 PM
Quote from: Paulcet on March 09, 2010, 12:03:49 PM
Neat concept. But can it do this?
http://www.youtube.com/watch?v=-cM9S2AzU28
http://www.youtube.com/watch?v=NG57XNgKPNU (http://www.youtube.com/watch?v=NG57XNgKPNU)
Watch the one in the quotes then watch this one. funny stuff.
:icon_lol: Hilarious!
Quote from: kml.krk on October 15, 2010, 11:53:48 AM
is that Porsche in the background of the first pic?
Looks like a 928. My favorite.
Quote from: kml.krk on October 15, 2010, 11:53:48 AM
nice progress. nice neighborhood ;) is that Porsche in the background of the first pic?
Yup... that would be my 94 968
(http://i28.photobucket.com/albums/c217/saxman242/968/968front.jpg)
(http://i28.photobucket.com/albums/c217/saxman242/968/9682258.jpg)
Very nice "I have the book" Been a Porche/VW fanatic since birth!
(http://i579.photobucket.com/albums/ss239/rtarpley/Smallwonder002.jpg)
Today's progress....
shaping is like 95% finished... now fun with surfacing and getting everything perfectly smooth. The carbon parts will have the same surface finish the plug I pull the final molds from does, so this will end up getting smoothed out with up to 2000 grit paper, then buffed and waxed before I pull molds.
(http://crecca.files.wordpress.com/2010/10/dsc00373trim.jpg)
(http://crecca.files.wordpress.com/2010/10/dsc00374trim.jpg)
(http://crecca.files.wordpress.com/2010/10/dsc00375trim.jpg)
Here's all the work on the bottom of the tank compared to a tank bottom straight out of the first mold. The sides were brought WAY down so it's nearly flush across the bottom, major flattening was done near the back of the tank to allow for mounts for the fuel pump to be attached in and the overall tank bottom has been smoothed to make it easier to lay up.
(http://crecca.files.wordpress.com/2010/10/dsc00376trim.jpg)
Seeing that you had a stand from harbor freight, I decided to look into it. I must say it is the best $40 I have ever spent. Excellent find, sir :thumb:
I'm sorry to ask, but what are the molds going to be used for?
My reading comprehension is not the best, but I believe it is to form a carbon fiber gas tank, modified to accommodate a fuel pump for his custom FI setup.
Quote from: ragecage23 on October 16, 2010, 10:39:04 PM
I'm sorry to ask, but what are the molds going to be used for?
Carbon fiber gas tank set up to accept a gsxr fuel pump for part of the fuel injection system.
Quote from: redhenracing2 on October 16, 2010, 10:50:20 PM
My reading comprehension is not the best, but I believe it is to form a carbon fiber gas tank, modified to accommodate a fuel pump for his custom FI setup.
Apparently you're 30 seconds faster than I am
Yet you are years ahead in fabrication technique :cheers:
Quote from: redhenracing2 on October 16, 2010, 10:58:38 PM
Yet you are years ahead in fabrication technique :cheers:
You too can spend endless hours in the garage sanding bondo.
I do paint and body work. Sanding bondo is one thing. Fabricating a carbon fiber gas tank from custom made molds to retrofit a fuel pump for my custom FI half gas/half miracle engine is another.
Quote from: redhenracing2 on October 16, 2010, 11:25:53 PM
I do paint and body work. Sanding bondo is one thing. Fabricating a carbon fiber gas tank from custom made molds to retrofit a fuel pump for my custom FI half gas/half miracle engine is another.
Well said, hell I can't do either the Bondo sanding or the fab like this gentleman possess.
Some of it is experience, some of it is education, but honestly, the biggest hurdle is just going for it. You'd be surprised what can be done if you dive in head first.
After WAY too many hours of sanding...
(http://crecca.files.wordpress.com/2010/10/p1010212trim.jpg)
About ready to start pulling molds.
hard to tell from the pic, but what are you going to do for the gas lid? doesnt appear to be inset like on the stock tank?
Quote from: jeremy_nash on October 22, 2010, 09:23:03 PM
hard to tell from the pic, but what are you going to do for the gas lid? doesnt appear to be inset like on the stock tank?
I have a low profile gas lid in the mail. When I pull the carbon part out, I'll bond it directly to the tank. It will stick up a little tiny bit.
cool, surely as detail oriented as you seem to be you didnt forget, was just curious what you were gonna use :thumb:
Quote from: jeremy_nash on October 23, 2010, 03:43:07 PM
cool, surely as detail oriented as you seem to be you didnt forget, was just curious what you were gonna use :thumb:
I'll post up pictures when I get to that step.
Popped the mold from the bottom of the tank just now. Easiest mold I've ever had release. Loving this new wax I'm using.
First mold piece. Needs trimmed and cleaned still.
(http://crecca.files.wordpress.com/2010/10/p1010217trim.jpg)
Bottom mold is out, cleaned up, and ready to go
(http://crecca.files.wordpress.com/2010/10/bottommoldtrim.jpg)
Started working on the top half.
A layer of plaster goes down and is allowed to dry. When I pull it off, it's perfectly shaped to the contour of the tank. I can then trace that onto a piece of wood and cut out the piece that will act as a parting line between the two halves of the top mold.
(http://crecca.files.wordpress.com/2010/10/partlinetrim.jpg)
Also, gas cap showed up from Hong Kong today. Not bad for $20.
(http://crecca.files.wordpress.com/2010/10/gascaptrim.jpg)
(http://crecca.files.wordpress.com/2010/10/tankwcaptrim.jpg)
(http://crecca.files.wordpress.com/2010/10/tophalfmoldtrim.jpg)
molds are coming along nicely
Today's work meant popping off the two top halves of my molds.
Before popping
(http://crecca.files.wordpress.com/2010/10/topmoldstrim.jpg)
Fresh off the plug. Came out beautifully
(http://crecca.files.wordpress.com/2010/10/onetoptrim.jpg)
All three molds fresh from the plug, almost ready to lay up carbon
(http://crecca.files.wordpress.com/2010/10/threemoldstrim.jpg)
(http://s3.amazonaws.com/advrider/lurker.gif)
Nice! That looks like a lot of work.
Quote from: GI_JO_NATHAN on October 28, 2010, 04:13:20 PM
Nice! That looks like a lot of work.
That's an understatement.
And this is how we make the bottom of a tank...
(http://crecca.files.wordpress.com/2010/10/bottomlayup.jpg)
Going to get 4 layers of 2x2 twill carbon, cut at 60 degree angles for maximum strength. Extra layer of carbon added where the mounts will go, and a layer of unidirectional carbon where the fuel pump will mount for a little extra strength.
Everything gets laid up on the mold, then a layer of peel ply added on top, followed by the red mesh to allow channels for air flow, then a cheap towel on top to soak up any extra resin.
Everything in the bag under vacuum...
(http://crecca.files.wordpress.com/2010/10/bottominbag.jpg)
The bottom of the tank should weigh in at under 200 grams.
Fresh from the mold
(http://crecca.files.wordpress.com/2010/10/moldbottom.jpg)
Trimmed up
(http://crecca.files.wordpress.com/2010/10/carbonbottom.jpg)
So if one were to want to learn to do this, would you have any good informational sources for this procedure? And where do you get the actual carbon fiber and resin from?
That looks pretty cool so far.
How do you plan to join the pieces of the tank together?
Quote from: dohabee on November 03, 2010, 05:18:25 PM
That looks pretty cool so far.
How do you plan to join the pieces of the tank together?
The molds were designed so that there's about a 2" overlap between the top piece and the bottom piece. I'll literally glue it together.
redhen... the forums over at fibreglast.com have some good information. I wouldn't recommend buying anything from them, their prices have always been highway robbery. I order most of my stuff through uscomposities.com
Wow, I forgot about this thread...great to see you're making progress :thumb:
Wasn't happy with how the bottom of the tank turned out. It had some wrinkles in it that would cause problems when I join the tank halves...
so I made another one
(http://crecca.files.wordpress.com/2010/11/newbottom.jpg)
New one on the right... used a different weave carbon, and added a layer of fiberglass to the top and bottom so there's no chance of reaction between the cf and the aluminum in the fuel pump. Just being overly cautious.
Also, worked on the throttle bodies for while. This is mocked up using an 01-03 gsxr 600 throttle body. I have a set of sv650 throttle bodies in the mail as well. We'll see if they work better.
(http://crecca.files.wordpress.com/2010/11/fimockup.jpg)
The new one looks much better, keep up the good work.
Quote from: redhenracing2 on November 04, 2010, 06:24:10 PM
The new one looks much better, keep up the good work.
Yup. I lost vacuum while the first one was curing. Caused it to pull up. The second one was actually laid up without the vacuum bag. Ordered some new sealant tape for my vacuum bags. Hopefully it'll work better when I do the top half of the tank.
Top part of the tank will have 2-3 layers of kevlar. Maybe I should name the bike bulletproof.
Humm I thought about this and Bullet Proof just didn't seem right to me. "Kojak" Tellie Savales?
Quote from: JB848 on November 05, 2010, 09:08:29 PM
Humm I thought about this and Bullet Proof just didn't seem right to me. "Kojak" Tellie Savales?
I would never actually call it bullet proof... none of the kevlar will ever be visible either, so it really wouldn't make much sense
SV650 throttle bodies showed up today. Now I get to disassemble, and find a way to make two into one... i.e. the sensors from each on only one throttle body.
These are way nicer than the gsxr units I was going to use, and have all the sensors I though I was going to have to fabricate mounts and such for, etc.
WAY larger too... which means they won't bolt up quite as easily, but that's ok, I'll just mill out some adapter plates.
sv throttle bodies unwrapped
(http://crecca.files.wordpress.com/2010/11/p1010213.jpg)
One torn down, with the gsxr throttle cable pulley attached (the other sv throttle body is the one with the cable pulley mounted). Secondary butterflies removed, secondary tps pulled.
(http://crecca.files.wordpress.com/2010/11/sidebysidethrottle.jpg)
Going to need to drill out a couple mounts for the fast idle valve and machine some spacers, but not that big of a deal. Also going to have to machine an adapter plate for the throttle body for the gs motor, but again, nothing major.
Amazing how much large than the gsxr throttle body (on the right in the pic) the sv unit is. Makes sense though... has to feed 325 cc instead of 125cc on the bike.
have you decided what you're going to use for engine management?
Quote from: aaronjosephward on November 11, 2010, 10:38:54 AM
have you decided what you're going to use for engine management?
Running a megasquirt ecu I built
(http://crecca.files.wordpress.com/2010/05/dsc00217a.jpg)
(http://crecca.files.wordpress.com/2010/05/dsc00216a.jpg)
My christmas present, ready to open this morning
(http://crecca.files.wordpress.com/2010/11/tankinbag.jpg)
Had to fight with the damn thing for an hour to get the tank out... but when I did...
Fresh from the mold
(http://crecca.files.wordpress.com/2010/11/tankfront.jpg)
(http://crecca.files.wordpress.com/2010/11/tankback.jpg)
(http://crecca.files.wordpress.com/2010/11/tank3quarter.jpg)
(http://crecca.files.wordpress.com/2010/11/kevlarlining.jpg)
Kevlar lined
And the money shot:
(http://crecca.files.wordpress.com/2010/11/cftankonbike.jpg)
Now with more gas cap
(http://crecca.files.wordpress.com/2010/11/bike1.jpg)
(http://crecca.files.wordpress.com/2010/11/bike3.jpg)
(http://crecca.files.wordpress.com/2010/11/bikefront.jpg)
(http://crecca.files.wordpress.com/2010/11/bikeside.jpg)
That is really cool! Do you have the bottom on it yet?
I wonder what the difference in weight between yours and the stock tank is?
I have a decent amount of work to do before I'm ready to attach the bottom to it. I did test fit and it fits great though.
The top half of the tank, with the gas cap weighs 2.2 lbs. Before adding the fuel pump, it'll probably weigh in around 5 lbs when all is said and done.
I originally purchases a set of throttle bodies from a GSXR600 to use for this project. I paid next to nothing for them because of some damage they had suffered. Unfortunately, the lacked some key components as well; most importantly, a fast idle valve, used to control the idle and air flow to the motor during warm up. After working with them for some time, I decided to go another route, and picked up a set of throttle bodies from an 03+ Suzuki SV650S. These throttle bodies are much larger in size, so there should be no question about them supporting the motor, they include all of the sensors I could need, and are better set up for running as individuals.
(http://crecca.files.wordpress.com/2010/11/p1010213.jpg)
Unfortunately, there are 2 throttle bodies here, with the sensors and valves needed split between them. For the bike, I need one throttle body that has the throttle plate to attach to the hand controls, the throttle position sensor, and the fast idle valve. To do this, I've taken the throttle body with the tps sensor attached, removed the throttle plate from the gsxr600 throttle bodies I was going to use, and modified it to work.
Here is the SV650 throttle body(left) next to the much smaller gsxr600 throttle body(right), with this modification already finished.
(http://crecca.files.wordpress.com/2010/11/sidebysidethrottle.jpg)
The fast idle valve will attach to the left side of the SV650 throttle body. To do this, I just need to drill out and tap two holes, create some spacers on the lathe, and bolt it up. An adapter plate to mount the throttle body to the motor will also be needed, however, none of this is a significant undertaking. Between this and the nearly finished gas tank, the fuel and ignition system for the bike is almost finished.
Very nice work! :bowdown:
Quote from: Paulcet on November 12, 2010, 04:55:43 AM
Very nice work! :bowdown:
Thanks. Popping the tank out of the mold was really nerve racking. So glad it worked out.
the second generation sv650 intake manifold boots happen to bolt right up to my GS motor... Going to save me a bit of machining.
(http://crecca.files.wordpress.com/2010/11/throttlebody.jpg)
(http://crecca.files.wordpress.com/2010/11/throttlebody2.jpg)
Much better with the new throttle body
did you take out the valves so they are always open and you get a pump stroke every revolution?
and is there going to be a pressure tank somewhere to smooth the intake pressure?
do you have mass air flow sensor with pressure for that megasquirt controller
Quote from: skirecs on November 17, 2010, 03:16:32 PM
did you take out the valves so they are always open and you get a pump stroke every revolution?
and is there going to be a pressure tank somewhere to smooth the intake pressure?
do you have mass air flow sensor with pressure for that megasquirt controller
Yes, the stock valves were removed on the side of the motor that's acting as a compressor.
(http://crecca.files.wordpress.com/2010/04/dsc00164.jpg)
Bit more details on page 2 of this thread if you're curious.
There will be a pressure tank before the throttle body. I may actually use an intercooler as my pressure tank so I can get air storage and cooling all in one.
I'll be using a map sensor instead of a maf sensor. Easier to set up and I've done a lot of tuning in the past with turbo motors running map sensors, so I'm more familiar with it.
Your valves on the combustion half are ugly.
Quote from: redhenracing2 on November 17, 2010, 03:38:50 PM
Your valves on the combustion half are ugly.
Busted motor that's just being used for fabrication of parts.
Ahh. I should have known better, with it being your quality work at hand.
I've got 3 GS motors sitting in the garage. No way I'd want to have that head anywhere near my bike ;)
(http://crecca.files.wordpress.com/2010/11/tankcapbonded.jpg)
Tank with the gas cap bonded into place. Same resin used for making the tank, thickened with glass microballoons. Hopefully no one will ever try to remove the screws holding the gas cap in place... they aren't going anywhere!
(http://crecca.files.wordpress.com/2010/11/cffuelpumpmount.jpg)
cf reinforcement for the fuel pump mount. Will be bonded to the bottom of the gas tank with studs running out the bottom for the fuel pump to mount to.
(http://crecca.files.wordpress.com/2010/11/throttlebodies.jpg)
The idle valve circled in red on the wrong throttle body. Tomorrow I'm going to the machine shop to do the work needed to put it on the right throttle body.
(http://crecca.files.wordpress.com/2010/11/iacvclearance.jpg)
Plenty of clearance with the idle valve in place though. :thumbup
Aluminum is on its way for the rear sets. Bought enough to make 3 sets.
Last night I placed the cf reinforcement for the fuel pump in the bottom of the tank and set some studs down through the tank
(http://crecca.files.wordpress.com/2010/11/fuelpumpstuds.jpg)
Now waiting for ups to show up with the tank sealer so I can start sealing the inside of the tank.
So I'm sitting here shopping online for some polystyrene foam so I can start prototyping the air tank for the bike. Can't find it anywhere. Look out the window, and a box truck from Bob's Foam Factory pulled up to the neighbor's house. Guess who carries the foam I need?
I need to start visiting the site more.. :icon_eek:
Sealant showed up yesterday in the mail.
(http://crecca.files.wordpress.com/2010/11/bottomsealant.jpg)
(http://crecca.files.wordpress.com/2010/11/topsealant.jpg)
It'll get a couple coats with the halves separated, then a little added after the tank is sealed to coat the edge.
(http://crecca.files.wordpress.com/2010/11/airtankv1.jpg)
started working on the air tank today. This is just a rough shape for a plenum. Volume is about 3 times that of a single cylinder. This is the proper size plenum design for a forced induction application.
A whole lot more pictures to follow from today's work when I upload them off the other camera.
Been working on getting everything mocked up on the bike.
(http://crecca.files.wordpress.com/2010/11/mockup.jpg)
Was planning on using the space between the subframe rails to place the ecu, etc... but this didn't actually leave anywhere for the rear tire to go when the suspension compresses.
With the stock rear fender in place it's obvious I have a serious shortage of space.
(http://crecca.files.wordpress.com/2010/11/noroom.jpg)
I don't have any intentions on ever running a passenger on the bike, especially since I've shortened the rear subframe and removed the passenger pegs, so I'll make some room in the seat itself. No need for any foam for the passenger to sit on, so I'll make a carbon seat cowl and remove all the seat foam and supports below it, giving me a place to put the ecu.
A well stretched trash bag over the seat provides a nice smooth surface, protects the seat for resin, and separates easily after the part dries.
(http://crecca.files.wordpress.com/2010/11/cowlbag.jpg)
An hour or so later, covered in fiberglass.
(http://crecca.files.wordpress.com/2010/11/cowlfiberglass.jpg)
So what do you do when it's too cold outside for the resin to cure but you have work to do?
Revert to your fort building days of your childhood!
chairs + blanket + space heater=
(http://crecca.files.wordpress.com/2010/11/fortoven1.jpg)
The FortOven
(http://crecca.files.wordpress.com/2010/11/fortoven2.jpg)
(http://crecca.files.wordpress.com/2010/11/fortoven3.jpg)
cf tank getting the two halves joined and the cf seat cowl curing
Are you going to make the seat cowl a solo seat design? I dont really like the look of some of the seat cowls on here, as they look like just a slip cover and I think if your gonna do that you might as well add a little different profile to it so that you can tell its there and not just a "hard seat".... :icon_lol: I know its more work but it sure does look a hellova lot better.
Quote from: Chanse on November 26, 2010, 06:52:11 PM
Are you going to make the seat cowl a solo seat design? I dont really like the look of some of the seat cowls on here, as they look like just a slip cover and I think if your gonna do that you might as well add a little different profile to it so that you can tell its there and not just a "hard seat".... :icon_lol: I know its more work but it sure does look a hellova lot better.
To start with, just a "hard seat", although this is on a corbin seat, which already is a bit more of a solo seat design, so we'll see.
I've been contemplating using an intercooler for my air tank for several month. Unfortunately, finding an intercooler small enough is a bit of a task. Finally got some dimensions on one of the smallest factory intercoolers available. This is from the mazda millenia. Apparently they run two small intercoolers.
(http://crecca.files.wordpress.com/2010/11/373483262_tp.jpg)
Unfortunately, the size is still on the large side for a bike. So I made a foam mock up to see if I could find somewhere it could fit.
(http://crecca.files.wordpress.com/2010/11/foamcooler.jpg)
This is about the best place I can find. Not sure how I feel about it.
(http://crecca.files.wordpress.com/2010/11/intercoolermockup.jpg)
Also picked up some foam today to start working on an idea I've had for some time for making carbon fiber charge pipes for the intake. I made a little 4" long section to test it out. We'll see if it worked or not after the resin cures.
CF charge pipes? yes please!
So the new method works as it should.
(http://crecca.files.wordpress.com/2010/11/cftube1.jpg)
(http://crecca.files.wordpress.com/2010/11/cftube2.jpg)
From foam to pipe in about 5 hours... not bad at all.
put the intercooler under the rear seat cowl with some sort of ducting
Quote from: skirecs on November 27, 2010, 12:04:17 PM
put the intercooler under the rear seat cowl with some sort of ducting
Doesn't leave me much space for the ecu and other electronics :(
cant fit the electronics in between the battery and the air filter? thats where im planning on putting mine
if the IC is in the cowling you could have some good air flow, better than under the seat
also if im looking at your air valves right it will be compressing air out the front right? why not switch the vavles so intake is in the front, exhast is the back, goes into the IC and then forward again to the IC, so it makes a loop?
Quote from: skirecs on November 27, 2010, 01:45:18 PM
also if im looking at your air valves right it will be compressing air out the front right? why not switch the vavles so intake is in the front, exhast is the back, goes into the IC and then forward again to the IC, so it makes a loop?
I've considered switching the valves, but clearances on the front make flipping the valves around a bit difficult. Also, concerns have been brought up when I discussed the idea with others about the intake and exhaust port sizes and losing some efficiency there. I'm still considering it though.
Quote from: skirecs on November 27, 2010, 01:33:11 PM
cant fit the electronics in between the battery and the air filter? thats where im planning on putting mine
if the IC is in the cowling you could have some good air flow, better than under the seat
I think it'd fit
(http://crecca.files.wordpress.com/2010/11/intercoolerrearseat.jpg)
but there's really hardly any air flow back there. Major low pressure area.
The under the seat idea was more for just an air tank, not an intercooler.
Quote from: skirecs on November 27, 2010, 01:33:11 PM
cant fit the electronics in between the battery and the air filter? thats where im planning on putting mine
Lots of electronics to fit in there
(http://crecca.files.wordpress.com/2010/11/electronics.jpg)
cf pipes look like they'll work well
(http://crecca.files.wordpress.com/2010/11/cfpipes.jpg)
and a few more pictures of the seat cowl
(http://crecca.files.wordpress.com/2010/11/seatcowl2.jpg)
(http://crecca.files.wordpress.com/2010/11/seatcowl.jpg)
i might have said it before... but I envy your fabrication skills.
Can't wait to see and hear this baby running.
Quote from: tb0lt on November 27, 2010, 04:26:00 PMCan't wait to see and hear this baby running.
You and me both
Quote from: saxman on November 27, 2010, 03:20:48 PM
Quote from: skirecs on November 27, 2010, 01:33:11 PM
cant fit the electronics in between the battery and the air filter? thats where im planning on putting mine
Lots of electronics to fit in there
(http://crecca.files.wordpress.com/2010/11/electronics.jpg)
truth, i forgot about the fuel controller
Since your doing the bike for 1 up anyways, why dont you cut the seat. Make the tall solo seat cowl and stuff some of the electronics there, since space is at a premium?
Quote from: Chanse on November 29, 2010, 07:34:50 AM
Since your doing the bike for 1 up anyways, why dont you cut the seat. Make the tall solo seat cowl and stuff some of the electronics there, since space is at a premium?
That's the whole point of the cf seat cowl that I made. Allows me to cut away the seat material under it, freeing up a lot of space.
Quote from: saxman on November 29, 2010, 01:06:28 PM
Quote from: Chanse on November 29, 2010, 07:34:50 AM
Since your doing the bike for 1 up anyways, why dont you cut the seat. Make the tall solo seat cowl and stuff some of the electronics there, since space is at a premium?
That's the whole point of the cf seat cowl that I made. Allows me to cut away the seat material under it, freeing up a lot of space.
I think he means making it taller so you have more room.
Exactamundo
ah, gotcha. If need be, I will. I think if I were to go that far though, I'd probably just do a tail swap.
So time for a bit more technical of an update. Lots of pictures, but not super exciting.
Spent the afternoon in the machine shop, getting the throttle body taken care of.
After removing the extra butterflies and linkages, I was left with a couple holes in the throttle body like so.
(http://crecca.files.wordpress.com/2010/11/tb1.jpg)
Obviously as this is a pressurized system, I can just have a hole.
The idle valve mounts to the other throttle body, so I had to make mounts for it. There were supports in the throttle body casting left over, but they weren't drilled out.
(http://crecca.files.wordpress.com/2010/11/tb2.jpg)
So I made a set of plugs for the holes to be press fit in. I also made a pair of spacers to properly position the idle valve in the same spot it sits on the other throttle body.
(http://crecca.files.wordpress.com/2010/11/tbspacers.jpg)
(http://crecca.files.wordpress.com/2010/11/tb5.jpg)
The actuator on the idle valve presses on a lever coming off the butterfly valve from the other throttle body. I had to take a section of a rod, thread it so that it would screw on to the butterfly valve rod, then press the actuator for the idle valve to it.
(http://crecca.files.wordpress.com/2010/11/tb3.jpg)
And we're ready to go.
(http://crecca.files.wordpress.com/2010/11/tb4.jpg)
WOW! :icon_eek: :bowdown:
Crazy.
After hours of test fitting, etc... This is really the only place the intercooler will fit.
(http://crecca.files.wordpress.com/2010/12/intercoolernaked.jpg)
Pros: Fits nicely, isn't obtrusive, distance between the throttle body and the air tank is minimal
Cons: Airflow is meh.
I'll have to get creative with some ducting.
The pipes will tuck into the frame right behind my legs.
(http://crecca.files.wordpress.com/2010/12/intercoolerlegclearance.jpg)
Found some room for the electronics.
(http://crecca.files.wordpress.com/2010/12/electronics-mock-up.jpg)
I need to actually cut a recess into the seat for the ecu to sit in though.
My Lithium Ion batteries to replace the stock battery showed up as well. Fit perfectly right up against the intercooler. I'll start with four and go to eight if needed. They stack up so nicely.
(http://crecca.files.wordpress.com/2010/12/battery-front.jpg)
(http://crecca.files.wordpress.com/2010/12/battery-side.jpg)
Hmm, first time I've noticed the almost carbon fiberesque fabric the seat is made from.
Was it too big to fit up front. Where the oil cooler goes on the newer models? Just a thought.
Quote from: Chanse on December 03, 2010, 02:34:55 AM
Was it too big to fit up front. Where the oil cooler goes on the newer models? Just a thought.
yes it is. Too thick. The core is a good 4-5" thick. Would hit the forks during any sort of turning
Have you thought about a 'fairing' or headlight mount with the intercooler and piping?. I imagine it being similar to the ram air tubes on the 4 cylinder bikes.
Also, I think the smallest automotive intercooler is the old Saab 900's, which also has the inlet outlet on the same side. It could be a worthwhile alternative to look at.
(http://i84.photobucket.com/albums/k22/awgy/Turbo%20build/SaabIC25ininlet-outlet.jpg)
Quote from: aaronjosephward on December 03, 2010, 09:53:14 AM
Have you thought about a 'fairing' or headlight mount with the intercooler and piping?. I imagine it being similar to the ram air tubes on the 4 cylinder bikes.
Also, I think the smallest automotive intercooler is the old Saab 900's, which also has the inlet outlet on the same side. It could be a worthwhile alternative to look at.
(http://i84.photobucket.com/albums/k22/awgy/Turbo%20build/SaabIC25ininlet-outlet.jpg)
The Saab intercoolers are much larger than they seem. I did look at them.
considered mounting it up front, but I'm not planning on running the bike fully faired so the aesthetics aren't there, and having that long of a pipe from the intercooler to the intake is far from ideal. The nice thing about this placement is that the pipe length from the intercooler to the intake is really short.
Looks great, maybe make some air ducts that come out of the side to wrangle in some air? Of course they would have to be carbon fiber.
Quote from: redhenracing2 on December 03, 2010, 01:35:13 PM
Looks great, maybe make some air ducts that come out of the side to wrangle in some air? Of course they would have to be carbon fiber.
I will, sooner or later.
And here's how we make carbon fiber charge pipes from holiday supplies.
Part 1
Start with a styrofoam wreath of the appropriate tube diameter. I'm using a 1.5" diameter pipe here.
(http://crecca.files.wordpress.com/2010/12/wreath.jpg)
Must be polystyrene foam, not polyurethane!
Cut into sections and glue together.
(http://crecca.files.wordpress.com/2010/12/pipetopview.jpg)
(http://crecca.files.wordpress.com/2010/12/wedgepipe.jpg)
Just like making an exhaust from u-bends.
Mock it up on the bike
(http://crecca.files.wordpress.com/2010/12/pipemockup.jpg)
Add some straight sections at the end.
(http://crecca.files.wordpress.com/2010/12/pipeplug.jpg)
To be continued this afternoon
Is it just me, or has the tank started to dull? The cowl looks dull too . . . is it just dusty?
Quote from: redhenracing2 on December 03, 2010, 02:33:26 PM
Is it just me, or has the tank started to dull? The cowl looks dull too . . . is it just dusty?
Both have been sanded down, but no finishing work done yet. They're on and off the bike so much at this point, they'd just end up getting scratched. I haven't even done a final trim on the cowl yet.
Looks pretty sweet. I swear I've seen a smaller inter cooler before..just can't remember where..
Cool beans. Are you gonna clear them or coat it in more resin?
Quote from: GI_JO_NATHAN on December 03, 2010, 02:44:02 PM
Looks pretty sweet. I swear I've seen a smaller inter cooler before..just can't remember where..
A buddy of mine with a turbo miata has a very small intercooler, but I think it's about the same as the one already being used here.
Quote from: redhenracing2 on December 03, 2010, 02:46:04 PM
A buddy of mine with a turbo miata has a very small intercooler, but I think it's about the same as the one already being used here.
Yeah I googled jet ski intercoolers but they're all water to air which of course wont work.
Quote from: redhenracing2 on December 03, 2010, 02:46:04 PM
Cool beans. Are you gonna clear them or coat it in more resin?
Both most likely. There are a couple low spots/pin holes that need a bit more resin to fill them in anyway.
What would be really cool (yet kind of ruin it at the same time) would be to go over it with a candy coat (a very light coat) to give it some color but still have the carbon look . . . just a thought. I guesss it would look like Joe Rocket's line of colored carbon fiber helmets.
Quote from: redhenracing2 on December 03, 2010, 04:19:10 PM
What would be really cool (yet kind of ruin it at the same time) would be to go over it with a candy coat (a very light coat) to give it some color but still have the carbon look . . . just a thought. I guesss it would look like Joe Rocket's line of colored carbon fiber helmets.
That's what colored carbon kevlar is for. They dye a kevlar cross weave to give it some color.
(http://img23.imageshack.us/img23/1919/minir53cap3.jpg)
I have a couple rolls of the stuff... Pretty cool
Making carbon pipes part 2:
This is the carbon I'm using.
(http://crecca.files.wordpress.com/2010/12/carbonsock3.jpg)
It's basically woven into a sleeve. Imagine a sock basically.
It stretches width wise pretty wide.
(http://crecca.files.wordpress.com/2010/12/carbonsock.jpg)
Take the earlier made foam pipe and cover it with a layer of carbon.
(http://crecca.files.wordpress.com/2010/12/carbonfirstlayer.jpg)
Resin is then worked into the carbon. Basically add a little, rub it in, working from the middle out. This gets rid of any air bubbles and compacts the layers together.
This is done for all the layers. I'm using 3 here because of how tight the weave is on this small of a pipe.
After, the pipe is tightly wrapped in several layers of peel ply.
(http://crecca.files.wordpress.com/2010/12/carbonpeelplysock.jpg)
This further compacts the layers, squeezes out any extra resin or air bubbles, and holds everything to the foam shape. Normally I use a special type of heat shrink for this, but I can't seem to find mine.
From here, the part is heated and left to cure for several hours.
Carbon charge pipes part 3:
Resin is hard. Pulled the peel ply off. 4 layers wrapped tightly = pain in the ass to remove.
(http://crecca.files.wordpress.com/2010/12/intakechargepipe1.jpg)
Fresh out of the peel ply.
At this point, you're saying... "but wait, these are wrapped around foam stupid!"
The amazing part about polystyrene foam is that it's soluble in gasoline or acetone. Pour some gas in, let it sit, and all the foam dissolves away.
Also finished the plug for the other charge pipe.
(http://crecca.files.wordpress.com/2010/12/enginechargepipemockup.jpg)
The tight u bend at the end had to be carved out of a block of foam. Very tedious.
(http://crecca.files.wordpress.com/2010/12/enginechargepipeplug.jpg)
I don't guess there's any way around that tight u-turn, seems like it would really reduce the efficiency of it. I'm just gonna stay out of it . . . .you got this. :thumb:
Quote from: redhenracing2 on December 03, 2010, 09:13:52 PM
I don't guess there's any way around that tight u-turn, seems like it would really reduce the efficiency of it. I'm just gonna stay out of it . . . .you got this. :thumb:
No way around it. I expanded the diameter through the u turn a bit as well which should help.
(http://crecca.files.wordpress.com/2010/12/cfintakechargepipe.jpg)
:bowdown: :bowdown:
that is the most technologically advanced GS mod I have seen so far.
I have seen some mechanically complex mods (czoko, jim knopf etc), but this one is truly one of a kind!
great progress!
Keep up the great work and awesome pics!
Quote from: kml.krk on December 04, 2010, 12:02:40 PM
that is the most technologically advanced GS mod I have seen so far.
I have seen some mechanically complex mods (czoko, jim knopf etc), but this one is truly one of a kind!
great progress!
Keep up the great work and awesome pics!
Yeah I agree. Although there is a FI turbo GS running around somewhere.
Quote from: GI_JO_NATHAN on December 04, 2010, 03:37:30 PM
Yeah I agree. Although there is a FI turbo GS running around somewhere.
But is one of his cylinders acting as a compressor? I would say this one takes it a step further. Right up there with Jim. Put them together on a project and see what happens :icon_twisted:
I know Im a little late beings how youve already done a crap load of work but I was also think up front lower to the bottom with inlet outlet facing up. But roll with what ya got. Cant wait to see this thing in action.
Quote from: Chanse on December 06, 2010, 04:50:16 PM
I know Im a little late beings how youve already done a crap load of work but I was also think up front lower to the bottom with inlet outlet facing up. But roll with what ya got. Cant wait to see this thing in action.
Really doesn't fit too well there... has to be way down on the ground to clear the wheel and right next to the exhaust would heat things up quite a bit.
Everything looks better with some gloss to it
(http://crecca.files.wordpress.com/2010/12/gloss1.jpg)
(http://crecca.files.wordpress.com/2010/12/gloss2.jpg)
Indeed it does. What did you use?
Quote from: saxman on December 03, 2010, 08:59:44 PM
The amazing part about polystyrene foam is that it's soluble in gasoline or acetone. Pour some gas in, let it sit, and all the foam dissolves away.
Yeah, polystyrene dissolved in gasoline or kerosene is not too dissimilar to napalm.
Quote from: redhenracing2 on December 10, 2010, 04:28:10 PM
Indeed it does. What did you use?
Just a light coating of resin, heated up a bit so it's self leveling.
Is there any advantage to doing that versus a clear coat? Extra strength maybe?
Quote from: redhenracing2 on December 11, 2010, 12:03:11 AM
Is there any advantage to doing that versus a clear coat? Extra strength maybe?
It does a better job of filling surface imperfections, etc. Unfortunately it adds weight. Doesn't do much of anything for strength.
Everything will eventually be sprayed with a uv resistant clear coat anyway.
I think this might tickle...
(http://crecca.files.wordpress.com/2010/12/bovtickler.jpg)
Short of a few hose connectors, all the mechanical systems are on the bike.
(http://crecca.files.wordpress.com/2010/12/mockupfinal.jpg)
(http://forums.offtopic.com/images/smilies/ohnoes.gif)
getting reeeally exciting :thumb:
Yeah I think your right that blow off valve under your crotch will probably tickle when it blows off.... pfsssssshhhhh..... lol
Got the wiring roughed in. Now just to do a little work to the ecu, and it should be ready to fire up!
Are you considering adding any sort of crash protection such as frame sliders or a cage?
If it were mine I think I would cry if I dropped it and damaged the carbon piping or the tank.
Do I spy prototype rearsets? Those weren't on it last page :woohoo:
Quote from: redhenracing2 on December 12, 2010, 03:38:16 PM
Do I spy prototype rearsets? Those weren't on it last page :woohoo:
(http://crecca.files.wordpress.com/2010/12/rearset3.jpg)
http://gstwins.com/gsboard/index.php?topic=54483.60
Quote from: dohabee on December 12, 2010, 03:37:52 PM
Are you considering adding any sort of crash protection such as frame sliders or a cage?
If it were mine I think I would cry if I dropped it and damaged the carbon piping or the tank.
:dunno_black: Haven't really thought about it. The piping isn't the end of the word if it gets damaged. It's cheap/easy to replace. The tank, however...
Nice man! Can't wait. Looks great if nothing else.
IT RUNS!
:woohoo:
Couldn't leave it running for long because it's late and the bike is REALLY REALLY loud
http://www.youtube.com/watch?v=rCzGMbHRFvE
(http://crecca.files.wordpress.com/2010/12/fireball.jpg)
Awesome screen shot from when I was trying to get it to start.
thats astonishing
great work
Ahh, I haven't followed up on the rearset thread in a while.
Glad it started, does it seem to run well/smoothly? Next vid needs to be fly-by :cheers:
Quote from: redhenracing2 on December 13, 2010, 12:43:18 AM
Ahh, I haven't followed up on the rearset thread in a while.
Glad it started, does it seem to run well/smoothly? Next vid needs to be fly-by :cheers:
I didn't let it run for more than about 5-10 seconds at a time because it's so damn loud and it was getting late.
There's a lot of tuning to be done before it's fly-by ready
Sounds alot like my lawn mower. single cylinder 4 stroke with a hole in the exhaust. I'm sure by the time you get it tuned up it will sing. well done :bowdown:
Holy awesome :bowdown: That kicks ass!
For those of you interested in the more technical side of my build, I'm updating my blog with a more formal write up of the science and fabrication methods used right now.
crecca.wordpress.com
So I've started putting some thought into how I want to do the body panels for the bike... and since I'm going really technical with everything else, I've started looking into building a 3d scanner so that I can scan the bike, design the body pieces on the computer, and cnc them out of high density foam. Then just pull molds for making the parts out of carbon off of that.
This 3d scanner software is awesome. Been playing with it all night.
Quote from: saxman on December 18, 2010, 02:31:10 AM
So I've started putting some thought into how I want to do the body panels for the bike... and since I'm going really technical with everything else, I've started looking into building a 3d scanner so that I can scan the bike, design the body pieces on the computer, and cnc them out of high density foam. Then just pull molds for making the parts out of carbon off of that.
This 3d scanner software is awesome. Been playing with it all night.
:bowdown:
Bought a new laser for the scanner today. I'll post up some pictures of what it's capable of after the laser shows up and I can play with it a bit more.
Wow that sounds pretty neat. Is this something that would've helped you out on the tank? Not that you needed any help. lol How's the tuning coming on the bike?
Quote from: GI_JO_NATHAN on December 19, 2010, 07:00:35 AM
Wow that sounds pretty neat. Is this something that would've helped you out on the tank? Not that you needed any help. lol How's the tuning coming on the bike?
Yes and no. The way I ended up making the tank, it wouldn't have helped. It would have required a different approach, but it would have allowed for me to make much bigger changes in the aesthetics of the bike with minimal effort.
I haven't worked on the tuning. Been really sick and dealing with finals for all my other classes. Probably won't get to dive into it until after Christmas.
This is beyond awesome. :bowdown:
...I had a goober question, but saw it was answered on the first page. Fantastic!
Any updates?
Quote from: KlaXon on December 25, 2010, 12:26:12 PM
Any updates?
Nope. Between being really sick all last week, finals, and the holidays, I've been super busy with other stuff.
Still waiting on my laser to show up then I have to set up a microcontroller for the laser scanner. When all is said and done, it'll be time to start scanning stuff.
Any news? The bike looks AMAZING, I wish I had the skill/budget to build a project like this.
Did anybody else ask about how this motor is expected to load the crank bearings differently, twist the crank, expand and contract unevenly with heat on one side, and etcetera? Not trying to be a wet blanket at all. I too am very impressed.
Quote from: karatechop5000 on January 16, 2011, 07:52:26 PM
Did anybody else ask about how this motor is expected to load the crank bearings differently, twist the crank, expand and contract unevenly with heat on one side, and etcetera? Not trying to be a wet blanket at all. I too am very impressed.
Loading on the crank bearings shouldn't really be all that different. Peak load remains constant as it occurs during the non combustion stroke.
The heat differential, however, may be a problem, and is part of the reason why I would have much preferred to do this with a vtwin instead of a parallel.
Just checking in to see if you've been able to work on the bike any.
Quote from: GI_JO_NATHAN on February 14, 2011, 09:36:04 AM
Just checking in to see if you've been able to work on the bike any.
Not much... shoulder deep in the job search and short on cash to make any big progress at the moment
Finally got the 3d scanner up and running. Needed it for a prototype project for a client, so spent the rest of the money needed. Thing is cool. Can't wait to try and make it work on the bike so I can start making progress again.
Quote from: saxman on March 10, 2011, 01:46:44 AM
Finally got the 3d scanner up and running. Needed it for a prototype project for a client, so spent the rest of the money needed. Thing is cool. Can't wait to try and make it work on the bike so I can start making progress again.
What model did you purchase? I've been 3D scanning for the past few years now (professionally) and have used some major work horse scanners.
I just read all twelve pages and it was like the best 12 page book I have ever read ( no not just because of all the pictures ) But it did help . Nice job man , do you think you'll meet your August dead line ?
Quote from: plewis51 on March 10, 2011, 07:29:49 AM
Quote from: saxman on March 10, 2011, 01:46:44 AM
Finally got the 3d scanner up and running. Needed it for a prototype project for a client, so spent the rest of the money needed. Thing is cool. Can't wait to try and make it work on the bike so I can start making progress again.
What model did you purchase? I've been 3D scanning for the past few years now (professionally) and have used some major work horse scanners.
Put together a system using the david scanner software. Amazing what can be done for <$100.
Quote from: atvwarrior on March 10, 2011, 01:31:00 PM
I just read all twelve pages and it was like the best 12 page book I have ever read ( no not just because of all the pictures ) But it did help . Nice job man , do you think you'll meet your August dead line ?
My deadline was actually about midway through december. I got the bike up and running by then, basically vastly surpassing anything and everything expected of me. Finished my degree, and am now spending all my time searching for a job. Looks like I'm probably going to end up getting a job at Northrop Grumman as a prototype design engineer, thanks in large part due to the bike. I started it as a resume piece, and it's done an excellent job of garner the attention I needed for getting me the job that I would like.
congrats on your new job! hope you will still have time to work on the bike.
it would be great to see it being ridden!
Quote from: kml.krk on March 10, 2011, 01:45:22 PM
congrats on your new job! hope you will still have time to work on the bike.
it would be great to see it being ridden!
Haven't been hired yet, but it's looking promising.
I should actually have more time/money to work on the bike after I get the job than before
In for updates?
which northrop location is it?