Lots of assembly required.....

Discussion in 'Some Assembly Required' started by CosentinoEngineering, Aug 29, 2011.

  1. sakurama

    sakurama on an endless build

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    Well, yeah, Chris has had some hard luck as of late. His car was stolen a few weeks back and wasn't covered so hard financial times probably got a lot harder and it's probably tough to do updates considering the situation. I know Chris and he's a fighter but when your ride is stolen it's a real tough pill to swallow. My motard was stolen a few years back from the same place - it just sucks.

    He'll be back though - it's not the first time his car was stolen...

    G
  2. DRjoe

    DRjoe Long timer

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    Sorry to hear about the car.
  3. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    Thieves suck. Remind me, why did we stop hanging horse thieves?
  4. diethornig

    diethornig Adventurer

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    Is that the one you're building? Hurray for you!!!:clap
  5. RecycledRS

    RecycledRS Along for the ride

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    Theft sucks. Hope you can get things going your way soon. Hang in there.
  6. DirtHopper

    DirtHopper Been here awhile

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    Because the world got all "PC" and civilized. we could solve a LOT of problems if we were to go to the ancient times of "eye for an eye":evil
  7. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    Sorry to drop off like that guys but the holidays started the diversion, then some work came in, then the universe decided to piss on my neck and tell me its raining again. Yes, car stolen always sucks. It was recovered with no tires, crash damage and no steering column so I'm not sure if I should be happy or not! the silver lining is that it is a Subaru and there is a lot of aluminum in it that I can sell to the scrap metal guy! Anyone need a 2003 WRX driveline? 68K miles runs great.

    At least the work that came in is interesting, it is converting the cast crankcases of a Yamaha TZ250 GP racebike to billet because of bearing insert and general availability issues. I just put a post on the blog site but here's a couple of images. The parts are pretty damn sweet if I may say so myself. So far these 2 parts produced 1 55gallon barrel of chips in addition to some bandsaw stock removal.

    The project is for Bruce Lind, a 250GP addict who still runs them all over the West Coast. He saw the V4 project somewhere on thew web and figured I could pull this off too. A couple of emails and phone calls later and I was on my way. a few months later and we're almost ready to assemble and test the first set of cases. Once they are proved out I'll make 10 or so sets for him. If anyone is in the market for a set contact Bruce and go from there. On the other hand, if anyone needs a part, engine, or bike reproduced then give me a call.


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    Once I'm done with a few more machining operations and a test assembly I can shift focus to the V4 project. I think the swingarm was the last post so next one will discuss the hows and whys of the chassis design.

    I definitely will not let another gap like this one happen. Sorry 'bout that.

    And thanks again for all the donations. T-shirts will be shipping out shortly to all. And the blocks will be going out for Nikisil plating!

    That's it for now.

    Chris
    http://moto2-usa.blogspot.com/
    Chip in and help!
  8. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    whale rider,

    Designing the output shaft and swingarm pivot to coincide would reduce chain tension issues but it is a serious packaging challenge to make a clean design. It also complicates sprocket and clutch plate changes, something that happens frequently on a racebike. The tension variation issue not that big these days as the use of long swingarms and short sprocket to swingarm pivot distances reduce the tension change to a small amount. On non-unit engine designs (vintage triumph and nortons, etc.) the tension variation is huge but its not so much on modern designs. Another factor is that my use of idlers to control squat behavior results in even less chain tension variation than a standard arrangement. The bottom line is that a small amount of chain tension variation is not a horrible thing so if you can easily eliminate it fine, but if it is a bear to eliminate then its not a big worry.

    As far as the steering damper position goes, the steer links and pivots from the 'handlebar' pivot to the upright pivot are pretty rigid so it will do a fine job where it is. If it was on the upright it would add a small amount to the sprung weight and further crowd a small critical area.

    >>I wish I was a millionaire and could get involved in this sort of thing.

    That makes 2 of us! ;)


    Chris
    http://moto2-usa.blogspot.com/
    Chip in and help!
  9. Flanny

    Flanny Flanny-it-up!

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    Wow Chris. That is unbelievable! Beauty in Billet!

    Hope for more V4 Updates soon!
  10. egoy2

    egoy2 perpetual n00b

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    Oh, yeah? Well I changed my own brake fluid!
    This is great stuff, Cosman. Thanks for sharing!
  11. Slimie

    Slimie Long timer

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    That crankcase is a work of art!

    A huge thank you for taking the time to share with us.

    -Simon
  12. CosentinoEngineering

    CosentinoEngineering Been here awhile

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  13. Roadracer_Al

    Roadracer_Al louder, louder, louder!

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    The crankcases are totally bad ass. Did you do anything special to retain the bearings?

    Nitrile rubber gloves from CostCo are your best friend. I have damaged my skin so badly over the years that I'm paranoid to touch anything chemical stronger than dish soap with bare hands.

    Regarding the Subie running gear, I don't know if this is a going deal or a fantasy, but my next door neighbors were talking about putting Subie running gear under a VW Vanagon to make a modern Japanese Synchro that can be daily driven and doesn't cost eleven-teen dollars every time something breaks. Totally wrong coast, though. I know you need a project like a hole in the head, but that powertrain would be supa' cool under a Thing or a Transporter.
  14. Mickldo

    Mickldo Been here awhile

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    I'm putting an EJ22 in a 77 Bay window Kombi at the moment.

    Have you seen http://www.subarugears.com/ When I do my next Kombi I want to do the whole 4wd thing and make a Syncro Baja Kombi Camper. [/hijack off]
  15. CosentinoEngineering

    CosentinoEngineering Been here awhile

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    The bearings have pins in the outer race to prevent rotation and SKF recommends a H7 housing tolerance for this application.

    As far as the subbie goes i'm just looking to convert it into as much cash as possible. No project vehicles for me, my hands are full!


    Chris
    http://moto2-usa.blogspot.com/
    Chip in and help!
  16. kpt4321

    kpt4321 Long timer

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    Chris-

    I've tried to get in touch with you via the email on your website but have had no luck.

    I'm semi-local to you, and I would LOVE to drop by and see what you are working on and have a chat. I'm a mechanical engineer and a bike nerd with a long history of love of motorsports, and I would really like to see up close what you are working on. I am in no way affiliated with your industry, so you don't have to worry about IP or anything like that. (I'm in composites automation). I'm just a nerdy kid who loves everything bike.

    If at all possible, please get in touch with me, either via PM here, or email.

    Sorry for the spam, all!
  17. Whale Rider

    Whale Rider Been here awhile

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    Thanks for the reply Chris, your TZ250 case is a work of art keep up the good work.
    WR
  18. SquirrelMilker

    SquirrelMilker Been here awhile

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    This is completely awesome. I love it. The whole deal. I watched a bit about Motoczysz building their bike in Seattle, WA. That was cool and still check their site often. I donated as well. Had to get a shirt!
  19. Lortdadu

    Lortdadu Joe Cool

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    Amazing work!

    Keep it up!

    I love it how you've explained details so that almost anyone could understand them! :thumb
  20. K0m4

    K0m4 Been here awhile

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    Totally awestruck. Talk about a non-compromise attitude: "I want the best front end I can imagine. Have to MAKE my own engine, and design a conceptually new frame to do it, but hey, anything worth doing is worth doing right"..

    Impressive, and here I am wishing I had the means just to fab my own brackets for a hugger...