Hybrid project

Show us that box of bits in your shed!
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JanBros
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Re: Hybrid project

Post by JanBros » Tue Jan 08, 2019 9:53 pm

I find that a very weird place to put it ?

Seems an "easy to damage place" in case of a crash, while there is so much space in between the frame .
and you are doing lots of stuff to save weight, and then you are gonna add, by welding extra studs and use long cables.
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Re: Hybrid project

Post by Gerrit » Tue Jan 08, 2019 11:10 pm

Suzuki XRs, Yamaha YZRs and even Kawasaki's X-09 have their coils, powervalve control boxes etc in similar positions on the frame, Jan. This gives easy access to the parts. See this Suzuki RGV500 as an example:
http://www.mcnews.com.au/1998-suzuki-rg ... clid=IwAR2
The EXUP's steel mounting bracket is only used temporarily to accurately position the pillars and then discarded. If I had machined the pillars myself I'd have given them a bobbin shape to save weight, but even as pure cylinders they aren't all that heavy- the pair only weigh about 40 g.
Anyway, the point is NOT to crash, surely?
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Re: Hybrid project

Post by 500bernie » Wed Jan 09, 2019 10:01 am

Hi Gerrit
When I saw the photo, I thought you were drilling through from the outside, but going to fit it on the inside.
I didn't realise that was the actual intended location for the servo.
I would have tried to mount it in the same location as the standard unit, just for simplicity.
Keep the photos coming 8)
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Re: Hybrid project

Post by c&c » Thu Jan 10, 2019 10:29 pm

As previously said some great workmanship here.👍.
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Re: Hybrid project

Post by Luders » Fri Jan 11, 2019 7:57 am

I'm also interested in the position choice. Are you doing something interesting in the space of its original position?

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Re: Hybrid project

Post by Gerrit » Sat Jan 12, 2019 12:31 pm

I haven't finalised my ideas yet, Luders, but I do want to keep all options regarding the space between the frame spars open.
By the way, can anybody suggest a source for a replica 4TW1 (1996 TZ250) fairing?
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Re: Hybrid project

Post by Luders » Sat Jan 12, 2019 2:55 pm

That space is prime for doing something with the airbox. I can't remember where I got my fairing from.

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Re: Hybrid project

Post by Gerrit » Sat May 18, 2019 1:33 pm

The ZXR400L upper fork yoke requires a bush (18.1 mm ID, 25.1 mm OD, length 20 mm) to be fitted to the steering stem bore because of the smaller diameter of the KR-1S stem:

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The bush OD and bore ID received a coating of green Loctite, after which the bush was pressed in place:

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Test fitting of the steering stem, it fits!

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Re: Hybrid project

Post by Gerrit » Thu May 23, 2019 12:39 pm

Next: get a bush made to downsize the bore in the ZXR400L lower fork yoke to take the KR steering stem:

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Re: Hybrid project

Post by Gerrit » Thu May 23, 2019 1:04 pm

The KR-1(S) rear shock linkage knuckle:

Image

Comparing the KR part with photos of the ZXR400 equivalent......

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..... and the EX250 knuckle........

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...... suggests the KR part is overengineered, so now to get a ZXR knuckle and compare the actual dimensions. I suspect some weight can be saved by trimming excess material from the KR knuckle. Photos of works Aprilia, Suzuki and Yamaha 250s in the Japanese "Racers" magazines indicate they have knuckles machined from solid, which all look lighter than the KR part.

Some EX models have a built-up knuckle:

Image

Presumably this is a steel part. Interestingly, Kawasaki's last 250 racer, the ill-fated X-09, had a knuckle similarly built up of aluminium so making such a part might be an alternative, albeit an expensive one. Not sure whether there is enough room to accommodate such a built-up knuckle, though, so this has to be checked with a cardboard template first.
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Re: Hybrid project

Post by JanBros » Thu May 23, 2019 7:29 pm

???

what is supposed to be over-engineerd about the KR knuckle ? it has a very basic shape with a lot of material left out where it is not needed.
And I doubt machining from solid will be lighter to. of course it can be lightened, but I wouldn't touch it (trim down), the weight gain will be minimal and you probably will weaken it.

It' s also one of the smallest knuckels in width, one from a ZXR needs much longer bolts.
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Re: Hybrid project

Post by Gerrit » Thu May 23, 2019 7:59 pm

That's why I want to compare the knuckles first, Jan. "Meten is weten", to measure is to know!
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