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Old 05-24-2013, 09:48 AM   #31
aposaric
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Please continue, this is going to be awesome :-)
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Old 05-24-2013, 04:11 PM   #32
XCgeek OP
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Originally Posted by andyhol View Post
whats the weight of the frame?
Great work with the reveal btw
The design weight without weld is just under 5kg. I weigh the actual frame at 5.2kg.

Does anyone know what a frame from an MX bike weighs?
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Old 05-24-2013, 08:55 PM   #33
anonny
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Very clever, I'm in.

Do you gave a budget in mind?
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Old 05-25-2013, 03:15 AM   #34
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Very clever, I'm in.

Do you gave a budget in mind?
Not really. Just what ver it takes to make it how I want it
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Old 05-25-2013, 04:48 AM   #35
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Now, I have brakes and forks for my build but there are some problems.

The brakes made by Formula and are from a mini KTM. An SX65 if a recall correctly. They are designed for axial mounts.

The forks are Marzocchi Monster T’s designed for downhill mountain bikes. They use a bicycle standard radial post mount.

The front hub is also a bicycle component using a bicycle standard IS 6 bolt disk mount.

The formula disk is a 5 bolt design.

Obviously none of these components simply bolt together and due to the mix of bicycle and motorcycle parts, there are no off the shelf adaptors available.

I guess if I can make a bike, I should be able to make a caliper mount so that is what I did.

The first problem I solved was the disk. This problem was easy and has given an opportunity to add some cool bling. An English bicycle component manufacture called Hope Tech make an ultra bling vented disk rotor. It is 200mm in diameter, which is a little smaller than I would like but with such a light design, it should work.







Next I modeled up the forks, hub, rotor and caliper in the CAD program and then designed a mount to interface them all.



Using the dimensions from the CAD model, I marked out the flat shape, drilled all the required mounting holes and the proceeded to fuck up the first on when I tried to bend it up into shape. Damn!



OK, lets make a second one and this time, I bought some 20mm x 20mm solid square bar to use as a former during the bending process. The former idea was much better as it meant I didn’t have to mark out bends and try to line them up. Plus, now I can use the same formers to make others if needed.

Here is the finished part and again all assembled on the forks.







Now back to the swing arm
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Old 05-25-2013, 09:25 AM   #36
Salsa
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I solved my problem this way.

Double Discs



Fabbing my own Hubs



Don
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Old 05-27-2013, 05:37 AM   #37
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After the frame, the swingarm becomes the next time to build.
The swingarm is built in largely the same way that the main frame was built and I promised a few more photos to document how I did it.

Like the main frame, a CAD model was made to get the size and shape correct. I then designed a jig that would locate and hold the three critical interface points (pivot, shock mount and axle).



Here is the jig assembled.



Then I got on my lathe and turned up the bearing housings, the tube connecting the two bearing housings and the shock mount items. Then I didn’t take any photos of them!

I bought some 5mm plate for the rear dropouts. I want these to be reasonably heavy duty as these items take all of the rear wheel input loads without any spring softening the input.

Ideally, I would send out a CAD file to some business that does NC profiling. NC profiling is expensive for small one off jobs so, like all the other plate components on my built, I will cut them out myself. I transfer all the key items (corners, holes etc) onto the plate, centre punch all the hole and internal corner centres. Drill out the internal corners and holes. Then use an angle grinder to cut out the shape.



You can see that only one dropout has the swingarm axle holes. That is because I want to drill both at the same time so that both plates match. Once the swingarm is welded, I will cut the material out to connect the holes making an adjustable slot.

The bearing housing and connecting tube are welded together with some temporary “bearings” in place and the swingarm axle to hold everything concentric. The bearing housing, shock pivot and dropouts are then fastened to the jig.





Next I make the tubes that connect all the critical item together. The first rule for a good weld is a good fit prior to welding so I am really trying to get better at this.







I continue fitting tubes working from most important to least.





That’s all for this post. Next time the swing arm should be completed.
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Old 05-27-2013, 05:45 AM   #38
sailah
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Great job on that swingarm. If you need stuff nc cut shoot me a pm and we can talk, I have access to a waterjet machine and postage would be reasonable.
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Old 05-27-2013, 05:58 AM   #39
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Great job on that swingarm. If you need stuff nc cut shoot me a pm and we can talk, I have access to a waterjet machine and postage would be reasonable.
Do you have access to Melbourne, Australia? Having a waterjet would be awsome
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Old 05-27-2013, 06:10 AM   #40
uraberg
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Subscribed. Ultralight bike is on my list of wants.
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Old 05-27-2013, 06:18 AM   #41
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This thread is so full of awesome. Really enjoying this project, XCgeek.

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Old 05-27-2013, 08:05 AM   #42
sailah
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Do you have access to Melbourne, Australia? Having a waterjet would be awsome
No but the post office does...send me a dxf file and I'll cut whatever you want for the cost of postage. It'll be an international collaboration
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Old 05-28-2013, 01:26 AM   #43
DRjoe
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No but the post office does...send me a dxf file and I'll cut whatever you want for the cost of postage. It'll be an international collaboration
Your going to regret saying that.

We'll all have you working 24 7 to complete our orders.
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Old 05-28-2013, 04:02 AM   #44
Pezz_gs
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Your going to regret saying that.

We'll all have you working 24 7 to complete our orders.
Yep, sure will

What was your drop box again Sailah
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Old 05-28-2013, 05:00 AM   #45
sailah
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Lets be reasonable about it now, I offered the op because he was cutting out those dropouts with a grinder. And a damn fine job he did I might add.

If you want something I'm happy to do it, just make a reasonable request and cover postage. I have plenty of scrap steel and aluminum laying around. Remember the reasonable request... since youre all from australia I could do one shipment and you could distribute...

$45 usd for a flat rate express envelope max 2 kg delivered in 3-5 days
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sailah screwed with this post 05-28-2013 at 05:06 AM
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