Power Steering Cooler – Update

The new power steering cooler is working well. There are no leaks with the new hoses, fittings and clamps. After a typical drive on suburban streets the cooler is warm but cool enough to be held in the hand without burning (sorry no definitive temperature measurements at the moment). Here’s a picture of it installed where it will get plenty of air flow.p1020090

Motard Complete & Tested

As mentioned previously on this blog, this is a motard style conversion of a Honda CRM 250 using a 2007 model Aprilia RS-125 wheels, discs and front brake caliper.

A custom bracket was designed in Solidworks to adapt the radially mounted caliper to the original brake caliper mounting holes. Designing in 3D allowed the part to be simulated (FEA) with heavy braking loads and calculate the factor of safety, stress, strain and distortion.

One of the advantages of using the Aprilia wheels over the popular wire spoke wheels is that they incorporate a cush-drive to reduce driveline vibrations. Continue reading Motard Complete & Tested

Workshop Projects

It has been very busy here with numerous projects but the main project has been a new simple CNC router.

P1010604 This is based on the “Mostly Printed CNC” machine that has featured on Hackaday, Thingiverse and other websites. This is small 3-axis machine with belt drives on the x & y axis. The z-axis has been upgraded to a lead-screw and nut.
The purpose of this machine is to get familiar with the software & hardware before commencing work on a larger platform router and then on to a third machine which should be a solid steel frame for machining metal parts. Continue reading Workshop Projects

APRILIA RS-125 CALIPER ON HONDA CRM-250

The APRILIA RS-125 caliper has finally been installed on the Honda CRM-250. The brake system has been bled with a quality DOT-4 brake fluid. It now has a solid feel (though there is some sponginess due to brake hose expansion – this may be replaced with a braided line) and no leeks in the system. So far low-speed testing has been carried out with further testing to come.

Continue reading APRILIA RS-125 CALIPER ON HONDA CRM-250

Replacing Obsolete Parts

This was a practical application of using 3D-printing to fabricate replacements for obsolete parts. The center caps for Holden Commodores with steel rims is a good addition to crate a tidy standard looking vehicle. These parts were commonly available and many were probably thrown away when steel rims were upgraded to alloy wheels but now a set can be from $100 – $180. Continue reading Replacing Obsolete Parts