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Offline Rouxman

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CNC Machining / Rally fairing project
« on: August 11, 2017, 06:59:53 pm »
Dawgs I need help please.....

I am in the process of "Macgyvering" a sort of rally screen on my X Challenge.

Rockfox sorted me out with the tower! Brilliant thanks!! Very helpful!!

I now need a mounting for the headstock.
Can anyone please advise where in the Cape Town (or surrounding areas) can I take my crude pencil drawing to be properly drafted and CNC machined and bent to shape for a reasonable amount. The bit of welding involved I can sort.

I need to end up with something like this...







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« Last Edit: August 14, 2017, 09:53:41 am by Rouxman »
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Offline Rouxman

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Re: CNC Machining
« Reply #1 on: August 11, 2017, 08:47:35 pm »
I need to have made the green part.




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Offline SteveD

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Re: CNC Machining
« Reply #2 on: August 12, 2017, 01:13:27 am »
This forum has unwritten rules, which may simply not be broken without unleashing fire and fury the likes of which not even Trump has seen before.
The first, and most important rule: Thou shalt not undertake awesome projects without a full writeup, preferably during development, with lots of peechas and humorous anecdotes to keep us lesser mortals amused.

Toe the line boet  :xxbah:

Your project looks awesome, tell us more. With humorous anecdotes.

Offline LionBuell

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Re: CNC Machining
« Reply #3 on: August 12, 2017, 03:34:30 am »
Rouxman. I can help with the CNC machining but I'm in joburg. If you don't win in cape-town pm me and I'll help you out.

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Offline tok-tokkie

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Re: CNC Machining
« Reply #4 on: August 12, 2017, 09:28:51 am »
That green part could be laser or water jet cut.  Then it needs to be bent to shape which you probably could do yourself.  Surly Rockfox can recommend a place.  Vulcan Steel in Montague Gardens could laser it for you but you must give them at least a fully dimensioned pencil drawing or a paper template that they can measure.

Offline Rouxman

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CNC Machining
« Reply #5 on: August 12, 2017, 01:39:41 pm »
This forum has unwritten rules, which may simply not be broken without unleashing fire and fury the likes of which not even Trump has seen before.
The first, and most important rule: Thou shalt not undertake awesome projects without a full writeup, preferably during development, with lots of peechas and humorous anecdotes to keep us lesser mortals amused.

Toe the line boet  :xxbah:

Your project looks awesome, tell us more. With humorous anecdotes.

SteveD, busted!!
My under cover project is now formally public and in the spirit of unwritten forum rules I shall oblige!!

Loved your project write up!! Read it all as part of my research!!

Tongue in cheek.....a copy of that Touratech bracket of yours would certainly speed up my project but wouldn't be nearly as much fun on my side
 



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« Last Edit: August 12, 2017, 03:00:11 pm by Rouxman »
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Offline Rouxman

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Re: CNC Machining
« Reply #6 on: August 12, 2017, 01:42:10 pm »
Rouxman. I can help with the CNC machining but I'm in joburg. If you don't win in cape-town pm me and I'll help you out.

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Cheers LionBuell!! As soon as I've completed my pencil drawing I will be in contact!!


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Offline Rouxman

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Re: CNC Machining
« Reply #7 on: August 12, 2017, 01:44:20 pm »
That green part could be laser or water jet cut.  Then it needs to be bent to shape which you probably could do yourself.  Surly Rockfox can recommend a place.  Vulcan Steel in Montague Gardens could laser it for you but you must give them at least a fully dimensioned pencil drawing or a paper template that they can measure.
Thanks tok-tokkie! I agree water jetting / laser is probably better options. I'll pop in to VS next week.


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Offline Rouxman

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« Reply #8 on: August 12, 2017, 02:16:51 pm »
This should probably be a "Pooratech" fred.....of my MacGyver X Challenge Rally Fairing install.

For some reason I feel absolutely compelled to add a rally style fairing / screen to my BMX despite my complete satisfaction with my current setup!!
I don't intend on using a road book or any of the rally required lectrics. I will however have a cool place to install my gps, 2nd aux power socket, spot switch and maybe an lCD rev counter.....who knows, the clocks my also move.....!





Ok so I've just about googled all the options out there!! I saw a guy who mounted a 1200gs screen and light setup to his bike. It looked pretty good.
Then I found a pic of a KTM 990 front fairing mounted to a BMX, also looked pretty awsome! Then there is the Touratech discontinued screen but eish, even it were still available....R15k.....I just cannot justify spending that kinda money on this pooratech project.

So I dug deeper and came across Rockfox. On their web they posted pics of the AT 1000cc made into a rally style bike. I zoomed into the pics and noticed the towers made from HDPE.

Rockfox AT bike


A quick call to Mike was followed by visit to Rockfox the following day where 30min later I walked out with a similar set. Real nice helpful guy!! They are in the process of setting up a workshop where you can go and make use of all the facilities, tools etc to build your own wet dream for a small monthly, pay as you go or membership fee. Brilliant and very affordable!!

Mike allowed me to take some pics of a similar setup to what he gave me from a project bike they are busy with. This might come in handy later....

Reference picture


So back at base I'm currently in the process of figuring out a bracket that will fit around the headstock similar to how Touratech mounted theirs. I don't fancy welding a bracket onto the headstock nor do I want to mount the tower to the yokes and have it turn with the bars. This leaves me with the most challenging option for this installation but I'm determined to proceed and succeed. Did I mention I'm not an engineer of any sort....?

I got two of each of these from Mike...



It should roughly sit about here. I plan to use the OEM light up front. The small OEM screen won't be part of the final product.


Preliminary positioning.....




Thus far following hours of measuring, drinking coffee, eating biltong, thinking some more, re measuring and drawing I have a scale drawing of the headstock assembly with measurements. I know someone will read this and offer that they could've supplied the info if I'd only asked. Well kind sir/madame, you are still welcome to share the info for cross referencing.

The drawing isn't complete as I currently only have port side. You'd be right in thinking that starboard side is the same however, BMW have kindly mounted a bunch of goodies like ABS block thingy starboard side. I also still need to draw the top view as this drawing will help me determine bend angles and total bracket length.

First drawing of headstock


Once this all is done I will cut out my designs from cardboard and make adjustments as required.

Right!! Back to work.....



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« Last Edit: August 12, 2017, 11:03:11 pm by Rouxman »
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Offline Rouxman

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« Reply #9 on: August 12, 2017, 05:39:45 pm »
Pisky en pater.....
This is going to be a late night


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« Last Edit: August 12, 2017, 05:40:28 pm by Rouxman »
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Offline 1ougat

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Re: CNC Machining
« Reply #10 on: August 12, 2017, 07:08:25 pm »
 :sip:
Make mine a Boxer with a shaft!!!!
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Offline Rouxman

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« Reply #11 on: August 12, 2017, 10:17:44 pm »
So far I have the following drawn up, top view, right and left brackets.

For a while I thought I was going to include the bottom plastic section of the tower into the aluminum. However, I've decided against it.

My thinking is that if I have a generic piece that fits onto the headstock I can play around with other HDPE parts in the future or if the current ones don't work out.

Also, the vrou is on the hunt for a X Country and I'm assuming she might also want some sort of screen. This generic arrangement will make it a bit simpler when her production requisition is submitted.


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« Last Edit: August 12, 2017, 10:31:53 pm by Rouxman »
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Offline Rouxman

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CNC Machining
« Reply #12 on: August 12, 2017, 10:19:47 pm »






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« Last Edit: August 12, 2017, 10:20:30 pm by Rouxman »
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Offline SteveD

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Re: CNC Machining
« Reply #13 on: August 13, 2017, 11:04:58 am »
SteveD, busted!!
My under cover project is now formally public and in the spirit of unwritten forum rules I shall oblige!!
Loved your project write up!! Read it all as part of my research!!
Tongue in cheek.....a copy of that Touratech bracket of yours would certainly speed up my project but wouldn't be nearly as much fun on my side

You set the bar high with your debut RR, this looks pretty awesome.
As you know, I have the TT tank and fairing, and I don't regret it for one minute. It was expensive, but for my easy touring style, the improvement in comfort is worth it.
I do feel a bit guilty that Touratech went bankrupt soon after I finished my build. It adds credibility to the rumours that I was a line item on their annual reports.

Online threeper

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Re: CNC Machining
« Reply #14 on: August 13, 2017, 11:25:39 am »
amazing job

Offline Rouxman

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Re: CNC Machining
« Reply #15 on: August 14, 2017, 09:50:46 am »


You set the bar high with your debut RR, this looks pretty awesome.
As you know, I have the TT tank and fairing, and I don't regret it for one minute. It was expensive, but for my easy touring style, the improvement in comfort is worth it.

[/quote]

It was back in 2009 in a Motorrad dealer I saw the X Challenge fully Touratech'ed for the first time.  It looked right and I knew that one day I would own one.  You confirmed the improvement in comfort and thus I will persevere to successful completion.   :salut:
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Offline Rouxman

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Re: CNC Machining
« Reply #16 on: August 14, 2017, 09:51:24 am »
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Offline Rouxman

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Re: CNC Machining / Rally fairing project
« Reply #17 on: August 17, 2017, 12:28:50 am »
Just a quick progress update.....

Once I completed all the rough sketches I made a plastic template to see if I'm close to where I need to be. It worked perfectly. Based on this I went ahead and drew the final drawings to scale.

The drawings are now being drafted digitally and I will soon have two pieces of aluminum that will hopefully fit around the headstock as planned.

I've made the decision to move the dials up onto the tower as well as it will just simplify wiring positioning.

I might also have to re route the throttle cable.....

Making the plastic mock up



Test fitting of the plastic mock up
 


Final sketches



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Offline MarioF650GS

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Re: CNC Machining / Rally fairing project
« Reply #18 on: August 17, 2017, 07:33:33 am »
Amazing job so far.... Following this one closely!

Offline Mike Adendorff

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Re: CNC Machining / Rally fairing project
« Reply #19 on: August 18, 2017, 08:30:43 am »
Hi Rouxman,

Jy weet mos waar ons sit,

Kom maak 'n draai met jou tekeninge en plastics en ons kan dit vir jou skets en laat of laser of waterjet sny en buig.

Laat weet maar dan kan jy ndie nuwe werkswinkel ook sien. :thumleft:
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