Quote from: coll0412Where is the good pic of the '89 clip on??

This is about as good as it gets right now...

http://www.jayspang.com/pics/gs500/004.jpg

Bike bandit shows the clip on to be bolted to the triple tree, so it could be easier to machine than I thought

I'll buy one.

from what I can gather I think your costs will be a bit more than $50 a clamp. I work in CAD / CNC projects at work and i can tell you for sure there is a fair bit of maching involved in this. You also have to take into account if the machine shop has right tools. how much bits are, how many steps in maching, programming time, how many you want. The more units they can run at once the cheaper. Because even if you want 1 or 100 it will still take same time for machine set up and programming.

I'm not trying to put you off, just giving you a realistic perspective on it.
I am currently setting up a service offering maching for engine side covers, swing arms pretty much and metal at all. I will do one offs or bulk. Basically i come up with designs (or customers own) and get them machined into engine side covers etc. Best customers are harley riders. (cause their all wankers ) they get their gang patch machined into their side cover. They like it and I charge them like a wounded bull !

I have a pretty sweet Japanese style dragon I am going to get machined into a small disc to replace the suzuki decals on engine side covers. Will post pics once done.

I like the dragon idea.  I'd love to see it when you're done.  

I will post some pics once i have it done. I am more than happy to do it for you people over there but with freight etc from the states to Australia might make it a bit more expensive.

But the plan is hopefully if it goes well I will get a dozen or so of these machined discs and freight for them would be fine. But for big things like side covers, swing arms it would porbably work out to be a fortune. Since you guys are over seas I have no problem sending you my CAD designs to see if you can find someone over there who can do them.

my standard file types are dxf,dwg,cad3,ascii. Or I can give it to you in plain old g-code


p.s. not that any of you probably care But Australia is going to the world cup !!!!!

We've got a CNC machine here on campus, so that helps me out a bit. Billet aluminum might be kinda pricey, so an Al alloy is where I'd probably go for this project. Also, I don't think the tube clamps are bolted to the triple. They are mounted to the plate that goes over the triple. There is the silver plate on top of the black triple.

I COULD design something that is similar to this, except that instead of the clamps being bolted on they would be integrated into the plate, making it one solid parts.

coll0412 - I'm not really THAT familiar, but I'd like to try it, just to increase my skills, if anything. I've been working with it for a few months now, so I've got a bit of it down. I'll probably design my own, as well as send you the dimensions in case you want to do it as well.

The clamps don't look as bad as I though. They're a solid rectagular block on bottom with a slot cut out, then an angled solid part along the right which then arcs over the top and down, meeting up with an extension of the bottom feature. Insert holes for the tubes and bolts, cut a slot out for the clamping, and fillet all the edges to make it stress less and bam, you got it. It might take me a few hours (or days, depending on my work schedule), but I think I could do it.

I'm still looking for a machinist here on campus that can help me out. I haven't had time to go down to the machine shop as I've been overloaded with Calculus and Chemistry homework.

The bolts that hold the clamps to the top plate and the ones that clamp the bars down... is it just me or are those allen heads? Anyone with an '89 know? There is a nuts and bolts store here where I can get lots of very nice stainless nuts and bolts for cheap. I'd have to include those in the package as well, but that's fairly easy.

Last thing: Do y'all think I should design one the way the '89 is exactly, or do you think I should modify it a bit, and how?

The bolts are allen heads, but ther are super wide grip length and relatively a small head. The threaded area is smallish too ... BTW those are same for a 90+ bike too. Just that you dont see it, its under the bars at the bottom of the pillow blocks. So just have the people use theirs.
Cool.
Srinath.

yeah cost is hard to determine since it may be hard to machine the triple tree top clamp thing. But since handle bars bolt on, it should make it a little easier, but i think you could save money buy making it a easiar to machine..(no fancy fillets since al 6061 should be plenty strong or no chamfer thing where the key goes) but that is just an idea.


As far as cost goes, setup costs are usually much more than material costs, my guess is if we could get 10 made probabaly about $100 to $125.
That would be just for the base, the addiational cost of the clamps for the handlebars plus handlebars yikes it could get spendy. But the more we make the cheaper it is...ahh economies of scale....

Sign me up, I'll put some money aside so I have the cash to pitch if it goes through.

I'm fairly certain the bars are just 7/8 inch tubes. Cut to length, smooth at the ends and shazam, you're good to go.

Are fillets really that hard to machine out? I have yet to get certified for our shop, so I'm not trained in the machines yet.

One thing I could do is machine it out cheaply (no fillets) and then smooth the edges myself. That could get REALLY time consuming though. If I've got a CNC machine, wouldn't the fillets be alright? I'd prefer having them on there and removing the cutout where the key goes if it needs to be one or the other. The fillets are more than strengthening features; they make it appear much more finished, cleaner.

For the price you listed, is that total cost to me for setup/materials, or is that the cost you think should be charged? I was going to start with around 10 anyways, because I'm sure there could be enough demand to sell those.

hmm..I thnk you mean the rounds, fillet is like a round between to perpedicular surfaces, and the fillet fills in between the two surfaces, a round is like around the outside of two perpedcular surfaces to remove material...so a fillet adds material between to perpedicular surfaces, and a round removes material from a perpedicular surface, in the eyes of building the model, its the exact opposite when you machine it.

To make it cheaper you want it so the CNC machine cuts out our patter, with rounds and holes and everything, the goes and makes a cut to remove material for the gage cluster mount. we would make ours a flat plate, i am not sure if thickness changes over the distince of the plate but we should  desgin it so we could use a common stock of plate al 6061

This seems like a cool idea.

One question though: What makes clip-ons so great? What is there to like. I have them, but don't know why they are so desirable. (even if there are people like RVertigo who don't desirable them)

Quote from: coll0412To make it cheaper you want it so the CNC machine cuts out our patter, with rounds and holes and everything, the goes and makes a cut to remove material for the gage cluster mount. we would make ours a flat plate, i am not sure if thickness changes over the distince of the plate but we should  desgin it so we could use a common stock of plate al 6061

I'm fairly certain the plate is the same thickness all the way through. I don't think there are any fillets on the clamps, though. The clamps are squared off and mount flush with the top plate, with a bit of the clamp going over the top of the plate. The top plate is the easy part. The clamps are going to be the tough parts. Convienently though, the clamps are exactly the same, so we've only got to design one.

Anyone with '89 clip ons going to be storing their bike over the winter and want to let me borrow their clip ons for design purposes?

Quote from: NightRyderWhat makes clip-ons so great?

Lower, more agressive riding position...  And looks.  Clip-ons are cooler, more "cafe" looking than a single bar.

I just couldn't stand city riding with bars that low...  I want higher ones when I'm in the city...  and lower ones when I'm on the freeway.  So, I guess mine are just right.  

I'd be up for for some clip ons for my 05.

I am currently trying to buy the triple tree clamp as we speak, so i think I will still need the handle bar holder, but maybe I can get some from someone on the forum  

You're getting the '89 top plate, but it doesn't come with the bars or clamps? That's odd. Where are you trying to buy it from?

It may come with them, the person is going to take a pic of it for me, even if it doesn't come with them, I can make my own holders or design some that are a little lower than the stock ones

I am also workin on seeing if I can modify the stock(non-89) triple tree clamp to work with bolt on clipons