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Nathan's motorcycles.....


flyingbrick

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Next up was the Exhaust hanger brackets which also hold the pillion pegs. These are cast aluminium, sculpted to suit the shape of the bike and they weigh 700g each! I love making carbon fibre stuff so I started really stretching my brain to figure out how on earth I could DIY produce something that is robust and aesthetically pleasing. These are made for MANY other bikes, but unfortunately not the busa.

First I took some measurements, then I guessed the bulk of the profile and made a thing in fusion 360. Eventually I'd like @ThePog to mill some MDF molds for me, but before then I need to make sure I can actually draw the thing properly in F360. This is TOUGH and requires skills that I don't yet have. V1 was printed overnight by legend @Roman so I could test fit it the next day. you can see that the mounting locations are all correct but the legs of the support exit the fairing in a less than ideal location (it needs to come further out as well as further forward)

one of my main problems is that I'm good at Draftsight but my licence has expired and I dont want to spend a few hundred on renewal :-( so am struggling along.

 

 

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  • 4 weeks later...

Disks to suit the zx10 wheels turned up and some little aluminium spacers are sitting at work. Aside from getting a tire fitted it's all ready now to go back together :smile: will be interesting to do a proper weight comparison (need to get tire pulled off the factory wheel first).

I have wanted aftermarket rearsets for ages but $$$ and I'm never happy with how the aftermarket rearsets all seem to be a series of aluminium plates stuck together with adaptors. Jankey as. 

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I decided to make my own, initially out of carbon fibre plates that would be waterjet cut. This was very very interesting as ended up using fusion 360's simulation package to calculate my designs strength. I ended up getting absolutely insanely strong parts designed in CF but at the last moment got a message from a friend (experienced in composites) saying STOP COME VISIT ME FIRST. 

He gave me an extremely valuable lesson on carbon fibre strength and how f360 was not actually giving me an accurate simulation, and although they may work, the properties of cf plate were always going to place a question mark over their suitability and working life, so back to the drawing board! 

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So I started again with grade 5 titanium. By this stage I'd stopped taking photos as I'd run so many simulations it was getting a bit old, but the results were good, the anticipated weight of each component was great, and I'd never played with titanium before so seemed like a good time. 

I sent some emails out within NZ and China. Its sad because companies in NZ really can't be fucked with smaller jobs and the associated admin. I got a few replies after waiting a few days and these replies ranged from not being able to secure the material (they couldn't be bothered) to having a minimum cut fee which made this only economically viable if I got three sets cut (I ain't paying for enough material to make that happen).

China made me feel like a king with absolutely great customer service, though I was still not 100% that I wasnt getting scammed... But after a few weeks my titanium rearset plates arrived!

I haven't had much time for filling around but need to tap some holes and buy some pegs, then they are good to go on permanently. Weight saving from the change to these Ti plates is 500g, however when I include the change to the associated light weight pegs, nicer bolts etc will be well over 1kg.

Colour change is due to some DIY anodising- super easy with titanium!! 

 

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The exhaust hanger thing was still Happening in the background. It's a tough shape that has to come out of the factory fairing in a very specific place. 

To double check it's shape (so that I didn't waste any more of Davids printer flament) I took a scan of the factory part and merged them together. This worked extremely well!! And yes, it fit. IMG20220613173510_copy_723x1600.thumb.jpg.3148e1c53cbf8fba5cebddcd0404dd20.jpg

Ali express provided a new light weight fuel cap for an insanely good price. Very happy with quality too

 

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  • 2 weeks later...

Left hand side peg assembly nearly complete. 

Carbon bars

Titanium bolts

Iv got some assembly to do once some fasteners etc arrive but on track to a 20kg reduction vs stock weight. Enough to be felt! Once assembled that will likely be the end of this project because any more weight removed becomes fairly expensive...unless I can be bothered trying to mold some fairings. 

 

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Edit. Just spotted, total is already 333g too optimistic as have counted front weights twice. 

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On 29/06/2022 at 17:03, flyingbrick said:

So I started again with grade 5 titanium. By this stage I'd stopped taking photos as I'd run so many simulations it was getting a bit old, but the results were good, the anticipated weight of each component was great, and I'd never played with titanium before so seemed like a good time. 

I sent some emails out within NZ and China. Its sad because companies in NZ really can't be fucked with smaller jobs and the associated admin. I got a few replies after waiting a few days and these replies ranged from not being able to secure the material (they couldn't be bothered) to having a minimum cut fee which made this only economically viable if I got three sets cut (I ain't paying for enough material to make that happen).

China made me feel like a king with absolutely great customer service, though I was still not 100% that I wasnt getting scammed... But after a few weeks my titanium rearset plates arrived!

I haven't had much time for filling around but need to tap some holes and buy some pegs, then they are good to go on permanently. Weight saving from the change to these Ti plates is 500g, however when I include the change to the associated light weight pegs, nicer bolts etc will be well over 1kg.

Colour change is due to some DIY anodising- super easy with titanium!! 

 

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Such a cool project, do you mind sharing the cost of the titanium cnc plates and the suppliers as this would be reallllllly useful.

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Nicely done.

Those carbon foot pegs look ultra slippery though!

I would highly recommend spending a few grams on some skateboard adhesive grip tape to put on them. I did this with the nylon pegs on my bucket racer and it makes a massive difference when you are riding. A+++ wouldn't ride again without it.

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5 hours ago, Willdat? said:

Such a cool project, do you mind sharing the cost of the titanium cnc plates and the suppliers as this would be reallllllly useful.

Of course.

I used a company called YUNCH, contact mandy.shi@yunch.tech. First class service. The cost of these two plates was just under $200. half of this was freight. Next time I'll be pushing for use of a cheaper freight option (But this was very fast, so i cant complain). One tip is to search AliExpress for services. Often they will have a product for $1usd. You purchase one unit, send them the drawing etc, get a price, then pay the rest of the bull by purchasing more units. This also means you get access to that super cheap (But slow) AE shipping.

Although that $200 may seem expensive, that is material, freight and cutting.

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4 hours ago, anglia4 said:

Nicely done.

Those carbon foot pegs look ultra slippery though!

I would highly recommend spending a few grams on some skateboard adhesive grip tape to put on them. I did this with the nylon pegs on my bucket racer and it makes a massive difference when you are riding. A+++ wouldn't ride again without it.

When I was picking up the aluminium bits from @Kimjon he says to me "how are you going to stop them being slippery"

I say, "im going to get some skateboard grip tape" and he's like " brb" comes back with a roll. Such a good chap! Grip tape is not on the pegs yet in the images- I wanted to abuse them a bit first with a hammer and with protected legs jumping up and down...it passed :grin:

He's also just machined up the steel pivot boss thing for my brake pedal. So dreamy.

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  • 4 weeks later...

Got my little aluminium spacers for the front discs (washers) and my titanium hardware, then had a new tire put on the zx10 wheel and the old tire pulled off the busa one.

580g of unsprung and rotational weight- damn happy with that!!

I then drilled some holes in the left side rear set plate and used gas and a form to bend some 6mm titanium rod to shape. I hammered it through the holes(was a right fit) then heated the ends with more gas and hammered/riveted the back side. Super happy with how that's turned out too!!!

Will clean up and re-anodise the whole lot, then final assembly :-D.

Oh and the black guard is a glass one for a gsxr1000. It saves 370g

 

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On 08/07/2022 at 14:20, flyingbrick said:

Although that $200 may seem expensive, that is material, freight and cutting.

Seems reasonable to me, I always think, 'how long would it take me make it by hand?' $200 doesn't seem bad for a part you know will fit first time.

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7 hours ago, Willdat? said:

Seems reasonable to me, I always think, 'how long would it take me make it by hand?' $200 doesn't seem bad for a part you know will fit first time.

Definately. Plus the material itself is pricy.

I justify it because I know if I don't pay someone else to do the hard stuff-i'll just never do it.

 

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