Tag Archives: homemade

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

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

Workshop Lighting

I recently added some LED lighting to my workshop. There are several “Star” type LED modules, as well as some MR16 downlights. These were situated above the work bench and helped to highlight the work area, two of the MR16 lamps also illuminated a dart board. I had the idea of hiding the dartboard lights underneath the shelf above the board which would also allow the lighting to be off the wall reducing the amount of shadows created. Continue reading Workshop Lighting

3D-Printed Tooling

When working on a Honda CRM 250 I needed to disassemble the engines water pump from the casing to replace the seal.

To do this the impeller needs to be unscrewed from the shaft. There is a hex on the nose of the impeller which can be gripped with a spanner or socket, the other side is not so easy. A lot of people simply jam a screwdriver in between the teeth of the plastic gear and the aluminium casing but I wasn’t happy that this would allow me to unscrew the impeller without damaging the gear. If you look closely in the photos you can see some cracks where the gear is pressed onto the shaft (apparently quite common on these engines). Continue reading 3D-Printed Tooling