Hotrodding the GS

Discussion in 'GS Boxers' started by Poolside, Nov 18, 2010.

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  1. Poolside

    Poolside Syndicated

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    <table border="0" cellpadding="5" width="650"><tr><td>Assembly report.

    Situation normal.

    The other day I posted the assembly schedule for the remaining orders.
    http://www.advrider.com/forums/showthread.php?p=16888000#post16888000

    Regarding that schedule, the 1st 30 pieces are on schedule. They went into the epoxy fixtures and finished the first cure stage, and are in the middle of the second cure period and will be shipped after that.

    But, early yesterday morning I found out there were a parts change with a vendor, and that caused some issues. JJ and I think we have them worked out. Here's what happened.

    I used all the vials during initial testing and these first batches, and had to order more. To me that's pretty exciting, re-ordering parts means the product is a small success!

    The current batch of 30 IICE Airs are in the background. The last of the vials went into building them.

    [​IMG]


    I started in doing the prep work for the vials, cutting, drilling etc., and everything was going smoothly. But then I noticed something, these new vials are not the same as the previous ones. The new vial is on the right in the picture below. The new plastic material is semi opaque, compared to the see-through material on the left.

    [​IMG]


    What the heck? Did I order the wrong part number? Nope. Let me check the distributor website. The product picture shown below is from their site, and is the same picture as last time. But this new part has slightly different dimensions than the previous part, and is molded from different material.

    [​IMG]


    The thing is, this new semi-opaque material isn't going to work. I need to see through the side wall of the vial in order to pour the epoxy to the correct level. You can't see much through this new material. Crud. Vendor changes of this sort is common enough when buying from distributors. But either way this is a heck of thing to find out at 3am on Tuesday morning with a deadline in front of you.

    [​IMG]


    Here's why the opaque material is a problem. If you remember from earlier reports, one of the final assembly steps is an epoxy potting process. The assembled IICE Air is mounted in a fixture to keep everything lined up while the epoxy is poured in and cures.

    [​IMG]


    The side wall of the vial must be clear enough to see through. At least well enough to pour the epoxy to the right level, and not overfill it. (Note: The silver wire 'stirrups' soldered into the board and passing through the vial are 'guy wires' to lash the vial firmly in place.)

    [​IMG]


    This is the perfect level. An epoxy overfill will 'flood' the jumper array.

    [​IMG]


    I spent much of the day yesterday trying to locate another source for the previous vial. Then JJ and I talked for a couple of hours about possible solutions. We discussed different ways to fixture the part. Some type of fixture that would hold the part in a way that I could look in through the open cap while pouring the epoxy.

    About 2 and half hours into it JJ came up with an idea! Leave it to Marketing!

    The excellent plan is to do the epoxy encapsulation in 2 separate pours. First a light pour, maybe 25% of the total amount needed. Let that cure and remove the part from the fixture. The cured epoxy from the first pour will hold everything in place without a fixture. Super! Open the vial cap and complete the second pour. You can see from the picture above, with the cap open, the epoxy level is clearly visible.

    Doing a primary 'short pour', and using the epoxy as a fixture, was a stroke of genius JJ!

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  2. grpweld

    grpweld Been here awhile

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    both of you are awesome!!!
  3. slowoldguy

    slowoldguy Tire Tester

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    There's a visual I didn't need.
  4. johnjen

    johnjen I've Been Resigned

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    Now along with marketings signature always positive can do attitude

    YES!™®©

    It should also be noted it has X-ray vision with which it can peer into the hearts and minds of ALL past and potential new customers alike. And now with these new fangled contraptions called confuzers it has a memory like an elephant. Which is to say, if it can just figure out how to push the right buttons, it can know all and see even more!

    And don't worry DELTATANGO you'll get your's :evil :norton



    Just as soon as we remember which buttons need to get pushed and in which order… :lol3

    YES!™®©
    marketing RULZ
    only apply to marketing



    JJ :rofl :lol3
    ps it won't be much longer now that we're in the home stretch.
  5. Poolside

    Poolside Syndicated

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    <table border="0" cellpadding="5" width="650"><tr><td>Yes the BP works (note: the initials BP refer to the Booster Plug), and so do the other competitive products. The significant issue with the other products is the improvement must stop there. Any attempt to improve the Transient Throttle fueling response will result in an overly rich mixture and less power. An over rich mixture feels the same as an over lean mixture, they both make less power.

    The upcoming IICE Cool product improves the Transient Throttle fueling response. And because the IICE Air is adjustable, the mixture stays right on the money.

    But enough about how great the IICE Air is, let's talk about your high-temp issue. I don't know exactly what you mean by "rattle the motor". I'm thinking maybe you mean pinging. And that the "rattling" happens at very low speeds or taking off. Can you clarify a little more what you mean, and what you're doing when it happens?

    My guess is, you mean begin with the bike at rest and the motor idling. Start advancing the throttle while engaging the clutch as quickly as possible. Let's call it the direct opposite of 'fanning' the clutch.

    [Edit] But that's just a guess, Phil. What's happening at the time, and what do you mean by "rattle"?

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  6. Poolside

    Poolside Syndicated

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    We're planning on one more big sale of IICE Airs before we turn our attention to the IICE Cool.

    I know, that doesn't answer the question. But that's the chronology. Details will follow.

    <BR>
  7. ghostrider1964

    ghostrider1964 Edumacated Red Neck

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    Just watchin:evil
  8. grpweld

    grpweld Been here awhile

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    whatchu talkin bout willis:huh
  9. slowoldguy

    slowoldguy Tire Tester

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    There is a post gone missing. ;) Now mine makes no sense at all. lol Just like most of my posts.
  10. Wallowa

    Wallowa Long timer

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    The rattle sounds like marbles in a can...I am assuming it is pre-ignition..it occurs when the bike is asked to provide a lot of grunt at very low RPMs when the engine is hot. Yes, as you guessed, when starting from a stop, loaded, hot day, hot engine it will sometimes rattle no matter how fast you dump the clutch and bring up the RPMs...a classic is also going very slowly up hill over "technical" loose/rocky/rutted off road paths when the engine is hot and you let the RPMs get below 2,000 [first gear] and suddenly need to increase your speed to save a slam-bang...roll on throttle and it can rattle briefly until RPMs build and torque kicks in to get the speed up...on difficult off road stuff you are often going to fast for good control of the bike in first gear if you keep the RPMs up; dog it down and it will rattle under a load. Hell, I have spun the back TKC to keep the RPMs up under the described situations on a hill, but that isn't always possible to do and stay in control of the dancing bike.
  11. Poolside

    Poolside Syndicated

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    <BR><table border="0" cellpadding="5" width="650"><tr><td>Assembly report.

    30 pieces are ready to go. I've been testing the new potting process talked about in the big post above so they aren't leaving today. Instead tomorrow. I'll print out shipping labels and post up an 'initials and state' list later tonight.
    </td></tr></table>
    [​IMG]


    <BR>
  12. slowoldguy

    slowoldguy Tire Tester

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    Please , God. I'm due for a break. Lemmee be the dude. Remember, no DB Texas. He passed away a while back. :cry It was sad but I sent a nice wreath from all of us at ADV. I'll miss the little feller.
  13. Poolside

    Poolside Syndicated

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    <BR>These 30 pieces are going to:

    D.S., TX
    J.L., NH
    D.R., CO
    B.W., FL
    T.R., DC
    M.B., CO
    J.L., CA
    K.J., AZ
    A.M., DC
    K.S., AK
    J.C., CA
    R.T., OR
    L.K., MN
    S.S., CA
    J.S., VA
    F.R., FL
    T.S., OR
    S.O., ID
    S.B., CA
    J.C., CA
    J.S., ID
    J.W., CA
    R.O., UT
    T.J., OK
    J.M., CA
    J.F., WA
    M.P., NY
    J.D., GA
    M.S., CA

    <table border="0" cellpadding="5" width="650"><tr><td>Regarding Track and Confirm numbers:
    For the last shipment I tried using the automated shipping notification through PayPal, but the feature doesn't work for multi-order shipments. I could post the tracking numbers up here, but then people could check the tracking number and see that J.T., CA lives in Long Beach 90803, for example. I don't know what degree of privacy everyone is comfortable with, so initials and state will have to do.

    They are shipping today, and depending on distance they arrive within 1 to 4 days.


    p.s.: Hey SOG, you guys are both in the next shipment. But I'll be sure to put the label on your envelope first. :D
    </td></tr></table>

    <BR>
  14. fooey

    fooey Live Bullet

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    I'll be looking for A F in OH soon maybe eh?:rofl
  15. frogy

    frogy Been here awhile

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    :baldy:baldy:baldy Oh well,looks like I'll have something to do over the winter.
  16. Plane Dr

    Plane Dr Been here awhile

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    Not to be confused with AF in TX who should be ahead of him.:D

    Not that I would undermine some one who uses eh, eh!:freaky
  17. Minnesota

    Minnesota Conform or be cast out

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    Still no WI. Why do you guys hate Wisconsin?

    :lol3
  18. ghgs

    ghgs Adventurer

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    I don't think they hate us, they just don't realize how soon it gets cold here...
    And after all, who in Wisconsin would ever need anything called an "IceCool" ??? When we get that for free...:rofl

    Sent from just south of the Frozen Tundra.:huh
  19. Andrew

    Andrew Optimus Primer Super Moderator

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    Well, to borrow a line from Dire Straits, "If two men say they're Jesus, one of them must be wrong."

    I'll volunteer to take the other's. :deal
  20. Codewheeney

    Codewheeney Hoopy Frood

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    w00t! And I get back from 8 weeks of travel tomorrow and I'm ready for some moto time.

    :ricky
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