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Re: My R4

Posted: Sat Jul 15, 2017 12:03 pm
by Variablevalves suck
Looking nice,
What's the headlight off?

Re: My R4

Posted: Sat Jul 15, 2017 12:34 pm
by Maelstrom
See the second post. They are 90mm Hella.
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Re: My R4

Posted: Fri Sep 08, 2017 12:31 pm
by Maelstrom
Long time no post.
Finally sorted out a design I like to mount the headlights. This is just a mock up. I will make some Ti panel washers etc for the final assembly.
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Re: My R4

Posted: Sat Apr 14, 2018 12:33 am
by Maelstrom
Another long time since posting. I bought a lathe and used that to make the bits and pieces from titanium to assemble the headlight bracket.
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and the assembly looks like this. The screws are supposed to be low head cap screws (they will fit flush) but I am waiting for those to arrive. The complete assembly without lights and adjustment screws weighs 270 grams, and with lights 1217. The standard 3TJ1 headlight weighs 1660 grams.
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Re: My R4

Posted: Sat Apr 14, 2018 12:41 am
by Maelstrom
Onto the next task, make a new titanium steering stem. The one I had made was not accurate enough and is now scrapped. Hence the need to buy my own lathe.
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I finished it to less than 10 microns, way better than was hoping for.
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Re: My R4

Posted: Sat Apr 14, 2018 12:48 am
by Maelstrom
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No, no, not Sharkenstein, Clampenstein!
Santa didn't bring me a CNC milling machine so have to do things the hard way.
Start with an R1 top clamp and bone saw,
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make jig
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perform clampectomy,
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and close wounds.
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Now a bit of tidying up and will be ready for paint. My Thai buddy let me attack his Hass VF7 VMC but I was ill prepared, so boring the front wheel to take the R1 bearings is not yet done and that is holding up the front end now. I have to work on the workholding for the wheel. We came up with a new plan but I am still worried about chatter.

Re: My R4

Posted: Sat Apr 14, 2018 12:52 am
by Maelstrom
After a Millennium:
Took a while to get the thread sorted but I just chased it with a threading die for the final pass. I finished the bearing journals on this stem to +/- 0.005mm. That is the machined finish, no polishing. I am glad that I bought the lathe and did it myself. Have not been able to get the wheel finished yet and nothing I can do about that. Can't ask my friend to stop making money on his machine just so I can use it. Next pic will be of the forks mounted into the frame.
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Re: My R4

Posted: Sat Sep 21, 2019 12:26 pm
by Maelstrom
Hi Guys,
Been a long delay in getting my front wheel bored to accept the R1 wheel bearings. Anyway here are the triple clamps after painting,
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and the wheels being measured after machining. In the first pic (LH side) you can see the bush I made to fill in the gap left by disposing of the speedo drive. Finished size is within 4 microns of my target. Gotta be happy with that.
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Re: My R4

Posted: Sat Sep 21, 2019 12:27 pm
by Maelstrom
Wheels powder coated so onto making axle spacers etc.
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Re: My R4

Posted: Sat Sep 21, 2019 12:27 pm
by Maelstrom
Got some Pirelli Angel GT2's, could not get a 120/60 for the front in Thailand so had to use a 120/70. Should be okay. The 400 disc centres are steel so I bought some el-cheapo chinese discs with alloy centres. If they wear out quickly, I think I can swap the rotors over by using some buttons I bought from the UK. Waiting for some genuine R1 caliper bolts to turn up and then I need to get a batch of fasteners nickel plated. After that the wheel go on and I can wheel the chassis out of the skull cave.
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