Rallye navigation bracket photo thread

Discussion in 'Racing' started by wrk2surf, May 4, 2011.

  1. Gros Buck

    Gros Buck Beef = Packed Vegetables

    Joined:
    Jun 29, 2006
    Oddometer:
    849
    Location:
    Quebec City, Canada
  2. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
    2,317
    Location:
    Some were in , lostralia

    But not
    cheap at over $600
    http://www.rallylights.com/detail.aspx?ID=5138

    I'd go a pair of baja designs squadrons for the cost of one of these hellas

    I have a pair of 90mm moduels on my 690 with HID kit and there are a fantastic light
  3. Gros Buck

    Gros Buck Beef = Packed Vegetables

    Joined:
    Jun 29, 2006
    Oddometer:
    849
    Location:
    Quebec City, Canada
    Not cheap, but cheaper if I buy directly in Europe. The 90 mm you have, were they originaly Halogen that you retrofitted into HID, or they were originaly HID ??? I'm asking cause the 90 mm HID high beam are only ECE and not D.O.T.

    Or were they bi-xenon ? If yes, I'd like to have an idea of the life of these modules under dual-sport conditions.

    Paul Jr 8
  4. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
    2,317
    Location:
    Some were in , lostralia
    I converted them with night stalker hid kit h9 type lamp cost about $500 including the pair of Hellas

    But now I'm looking at the BD squadrons so I can get rid of the birds nest of ballasts and wiring

    As I said fantastic light output I got excited on night ride in the Aussie hicountry found myself doing 140kph
  5. 640 Armageddon

    640 Armageddon Do or Do Not. There is no try.

    Joined:
    Mar 4, 2009
    Oddometer:
    3,558
    Location:
    Greece
    I have thought about shear bolts too. Notches on the aluminium or whatever material since we put more than one on the table, may also help. But there is a problem in this particular situation. The bike is going up and down,
    Jumping around and occasionally having small crashes. If you have such a design you have to make sure that it will not break during riding... This may be very dangerous for the rider. That is the advantage of hdpe in certain places. It gives some room and comes back. There are too many variables too make a part that will self destruct safely in a crash. I think this could have been implemented by the teams but there is a reason that it has not been done.

    My 2 c...

    TheAntiPaul has done a great job here, as always, and as he says you don't have to worry about fatigue cracks... A big bonus if youowe a 640 adv... Composites are the other way, which I like a lot, but for sure more expensive and not for theinexperienced manufacturer...

    Sharing knowledge is the beauty of this thread!
  6. Joe Watson

    Joe Watson Long timer

    Joined:
    Jul 20, 2008
    Oddometer:
    1,034
    Location:
    Sunshine Coast, Qld, Aus.
    Well my project is nearly over. Just tidy up a bit of wiring, a sticker kit and some headlight protectors and she is done:

    [​IMG]

    [​IMG]

    [​IMG]

    Got her out for a ride after the fairing had been modified and painted. All holding together well so far:

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Thank you to everyone in this thread, you have helped me out, inspired me and directed me. I appreciate it.
  7. Hayduke

    Hayduke ///SAFETY THIRD/// Super Moderator

    Joined:
    Jun 8, 2004
    Oddometer:
    45,088
    Location:
    Salida, coloRADo
    looks great!
  8. wrk2surf

    wrk2surf on the gas or brakes

    Joined:
    Dec 16, 2007
    Oddometer:
    7,736
    Location:
    THE exact center of California/Bass lake/Yosemite
    awesome! Good to see the adventure faring put to good use!
  9. Gros Buck

    Gros Buck Beef = Packed Vegetables

    Joined:
    Jun 29, 2006
    Oddometer:
    849
    Location:
    Quebec City, Canada
    In general, nice DIY, but I'm scratching my head on that Zumo though. The GPS is particularly fragile. Pins on the connector eat them self up with galvanic corrosion. Here in north-America, Topo maps looks pretty uggly.

    Paul Jr
  10. Deadly99

    Deadly99 Fast and Far

    Joined:
    Apr 8, 2008
    Oddometer:
    11,341
    Location:
    Merrickville, Canada
    Very nice :thumb


  11. Mudguts

    Mudguts when in doubt GAS IT

    Joined:
    Jan 16, 2006
    Oddometer:
    2,317
    Location:
    Some were in , lostralia
    Lookin Sweet Joe :evil
  12. Joe Watson

    Joe Watson Long timer

    Joined:
    Jul 20, 2008
    Oddometer:
    1,034
    Location:
    Sunshine Coast, Qld, Aus.
    Thanks for all the great comments everyone. I can't wait to see it finished and all stickered up!


    Paul, I have no idea what you are talking about?? I have had the Zumo 550 now for over 4 years and it has been anything but fragile!! I absolutely LOVE my Zumo and would buy another one in a heartbeat.
  13. theantipaul

    theantipaul Reforming Neandertal

    Joined:
    Nov 2, 2008
    Oddometer:
    1,552
    Location:
    Niwot
    Joe what you've done there is great, shows what you can get done with a little equipment and a lot of skill!

    Did some more destructive testing today, videos later,

    [​IMG]
  14. theantipaul

    theantipaul Reforming Neandertal

    Joined:
    Nov 2, 2008
    Oddometer:
    1,552
    Location:
    Niwot
    Can't wait to see what you've come up with Jr.
  15. Gros Buck

    Gros Buck Beef = Packed Vegetables

    Joined:
    Jun 29, 2006
    Oddometer:
    849
    Location:
    Quebec City, Canada
    It will be simpler because of simpler needs. Nothing anybody here needs. I need something WIDER cause I want to put two 90 mm BI-LED lamps. Which means 100 mm in between.

    It will be made out of 7078 aluminum and punched with fluted-then-"helicoil"-ed 8 mm holes (fine thread) everywhere. So that I could add things up everywhere.

    I will make it specifically for the 690. Will not fit anywhere else most probably. I do not intend to sell it anyway.

    And fix it to the bar riser I'm currently building using 3 ram mount balls. Two on the top triple clamp, and only one on the bottom triple clamp. Cause the lower triple clamp is sometime not in-line with the top one. Specially after a crash. :deal

    I will re-localize the display further up.

    Paul Jr 8
  16. theantipaul

    theantipaul Reforming Neandertal

    Joined:
    Nov 2, 2008
    Oddometer:
    1,552
    Location:
    Niwot
    The issue of rider safety has pretty much eluded me, so when Mudguts & Armageddon started talking break away devices, I tried to apply it to the tower. With the HDPE side plates you'd have to use more then 2 bolts to keep the RB mount from moving since the HDPE is so slick, then you'd need more force to overcome the fasteners, sheer the plastic and have it pivot out of the way when your body moves over the bars dynamically.

    [​IMG]

    That piece was 3/16" thick with a .090 wall around the mounting bolt, bolts up marginally and shears pretty easy. That will most likely need some tweaking, but seems plausible as a solution without having components separated from the tower. Easily fixed on the trail and I think dirt cheap insurance

    Then decided to take the rest to failure with a 5lb deadblow mallet, both pieces are 1/4" HDPE the white is natural, the black is marine grade. I now have no doubt that if the Nav components are taking the brunt of the impact they will move to an extent, absorbing and dissipating the impact and spring back to an extent. How much? Depends on the impact.


    [​IMG]

    [​IMG]

    The results, after repeated blows continuing to the edges of the supports, the HDPE shears out the bolts and deforms plastically.

    [​IMG]

    Thoughts?
  17. wrk2surf

    wrk2surf on the gas or brakes

    Joined:
    Dec 16, 2007
    Oddometer:
    7,736
    Location:
    THE exact center of California/Bass lake/Yosemite
    As someone said earlier, many riders including Meoni have been injured or killed by towers.. I know since riding with mine i have always had a chest protector but have slammed it a couple of times on slow speed.. that is not what im worried about my concern is a high speed get off over 50/60 mph where it seems this idea would really do the trick as long as you had a spare or two.. to keep in the rally!

    on top of it all im sure it is much more vibration resistant..

    I would use it!

    BTW.. I sure wished I lived close to your shop!
  18. jesusgatos

    jesusgatos fishing with dynamite

    Joined:
    Nov 17, 2006
    Oddometer:
    2,451
    Location:
    on the road
    That's a great idea Paul, and think it's a winner if you refine the geometry (maybe move the pivot-point back so there's no chance that any kind of top-down impact could be inline with the pivot/bracket). Sorry, that might not be clear. What I'm trying to say is that if you move the pivot-point back, it'll be more likely to collapse under any kind of top-down impact.
  19. Gany

    Gany Been here awhile

    Joined:
    Apr 30, 2007
    Oddometer:
    517
    Location:
    Melbourne, Au
    Nice work Paul! Love to see the equivalent video with aluminium uprights!

    Are the holes less likely to shear with thicker spacers?

    Wonder if the white piece or some other piece could be designed so that it moved rather than failed, without it moving under normal riding conditions? Picture something like the white piece that was a hook, so an impact would cause the bolt to force out of the hook allowing the tower to move hopefully without destroying the white piece. You could then either unbolt or force it back into the hook and keep going? Or something like a string of holes joined together but where the holes touch its say half the thickness of the bolt so the plastic has to compress to allow the bolt past it.

    Anyhow, food for thought.

    I was going to run with 10mm thick HDPE but based on your testing it seems ~6mm/ 1/4" will hold up just fine!

    Keep it coming!!
  20. jesusgatos

    jesusgatos fishing with dynamite

    Joined:
    Nov 17, 2006
    Oddometer:
    2,451
    Location:
    on the road
    Hard to say without seeing a whole assembly, but also looks like you might be able to make the two main vertical sideplates shorter. The more compact you can make that part of the assembly, the better.