Tuesday, April 24, 2012

Mid Control Fab.

For the foot controls on the turbo bike i decided to build them from scratch since i was having a hard tome coming up with something that looked unique and had the proper positioning. After designing the parts on the computer i had them laser cut out of .375in plate. Once the fit and function has been fully tested i will massage all the parts to give them a more organic feel. 

 Here is the brake lever after being laser cut. 

 The lever needs a bit of a zig zag to clear the cam cover so i heated it up with a torch and formed it over this round stock. 

 Here is the test fitting of the lever. It still needs some fine tuning but its close. 

Anytime i can make something that will work with a factory part it makes life easier down the road. here is a clevis that can utilize basically any stock HD peg. 

 The rear drum is cable actuated and the cable will pull via an arm that is indexed on this shaft with this square drive. 

 Test fitting the square to make sure it fits. The opening on the bottom of the lever arm is for the brake light actuator. 

 As you can see the arm will be fixed to the shaft by a 5/16-18 bolt and washer. 

 Brass bushings get pressed into the mid plate so that the brake system doesn't bind up and wear out. 

 Top view with arm, mid plate, bushings, and brake lever installed.

Side view of the assembly.

Possibly One Of The Best Rides Ever.

Friday, April 20, 2012

Intake clamps.

This carb to turbo adapter has been kicking my ass lately trying to figure out how to make it work.  Lastnight i finally figured out how to do it.

 The problem is space, i want to keep all this turbo stuff contained. nothing bothers me more than having hose clamps and crap flying all over the place. every turbo setup i have seen looks like a jumbled mess, so i am really trying to simplify everything.  The carb is bounded by the rocker box, breather bolt, and fairing side panel.  Th carb needs to sit to the right about .5in in order to not inter fear with the rocker box, it also needs to gain about .5in in dia. interesting how that works out?

After rummaging around the shop i found this piece of scrap aluminum that looks about perfect for the job at hand. 

 Dropped it into the lathe and got rid of some of the extra material that was not needed.

 The .75in center hole was already drilled in the part this actually ended up being really handy as a point to index off of. The carb needed a hole 1.80in so i machined a hole 1.805in to allow for a nice slip fit. (its really snug). After machining the main carb hole I added the first port which created the passage way from side A to side B this was 1.65in ID.

 Once I test fitted the part on the carb it was time to work on the outer portion of the clamp.  220 degree sweep pretty well took care of it. after the arc was cut i placed the mill on the start and end points and drove it straight out on the x axis to create parallel flats.

 Here i am using a key way cutter to detach the clamp from the rest of the manifold.

 Using a .065 end mill i cut a slot to give the clamp some room to compress. This will be a bit experimental but i did not run the mill all the way through into the intake port. i stopped about .032 away, hopefully this will allow the clamp to tighten up enough really clamp down tightly.

 Here is the turbo side of the manifold. i opened it up with a .75in ball end mill to aid in intake flow.

 Clamped it in the lathe to turn down some extra material and smooth out any rough patches.

 I did a little porting on it by hand with a barrel sander to make for a smooth transition from carb to turbo.

 This is the manifold welded to a v-band flange that mates to the turbo.

here is it all mounted to the bike. I still need to machine the pinch bolt hole and counter bore on the clamp, but it was 1:30am when i made this so i will save that for another day. 

Jeremy Miller

Jeremy Miller of JMILLSENT  is making an awesome video for the born free bike. He cam over on monday with his crew and they got buck wild in the shop. i can't wait to see the final product. Thank you guys. 

Thursday, April 12, 2012

BF4 Bike update.

I have had a bunch of people email asking about my bike for born free saying they can't find any info about it. i have a separate blog for the bike. i have decided to just post updates on here since i always slack on this blog anyways. 

here is how the bike sits today. i bailed on the aluminum fairing because it just wasn't turning out like how i had it in my head. this one weighs about a quarter of what the metal one weighs as well.  i am going to run cam locks (improved version of dzus fasteners) on it so the entire fairing can be released with a couple turns of a screw driver. the bike is coming together really nicely but i still have a mile long list to widdle down before its test ride time. i can't wait to hear how the turbo sounds! 

Tuesday, April 3, 2012

Bf4 Bike update.

I have been working on the turbo bike every now and then at night, the show is going to be here before we know it.  here is my list of things to get done before here and there. i better start late nighting it if i want to have this thing licked by then.