A recent inspection on a Holden Commodore revealed that the power steering cooler was leaking. The standard cooler is a length of 3/8″ steel tube running horizontally in front of the radiator. These are known for rusting and splitting or leaking fluid. Below is a close up of the part that was removed.
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
It has been very busy here with numerous projects but the main project has been a new simple CNC router.
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
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.
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
With the development of so many consumer, DIY and kit CNC mills, lathes, Laser-cutters, 3D-printers and other assorted NC machines that line our wishlists it can be easy to forget that a lot can be accomplished with manual tooling.
A recent project was figuring out how to adapting a YZ-125 motorbike engine to a go-kart frame.
A kart usually has two parallel tubes to mount an engine to sometimes a flat plate that is welded into the frame. A motorbike on the other hand has a frame that encircles the engine or even uses the engine as a stressed member forming part of the chassis. The kart for this engine had a flat steel plate with a few slotted holes to bolt the engine in place and was situated behind the axle close to the centerline. Continue reading Adapting a Motorcycle Engine to a Go-Kart
The calipers have been dis-assembled and inspected. The castings of the inner and outer caliper halves are symmetrical, front to rear, and could be machined to suit either the left or right hand side fork of the motorbike.
Now onto the inspection…
Recently turned a few spacers on the lathe for the CRM to motard conversion (see earlier posts – CRM 250 with Aprilia RS-125 wheels & brakes).
The fabrication of the motard bracket, to adapt the Aprilia RS-125 radial mounted caliper to the Honda CRM-250 front forks, is now complete and the results are quite pleasing.