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The first thing is the brake pedal. With the pivot point being in a completely different place than any "stock" CR, a stock pedal just wouldn't fit. So I've had to make one. I've still got a little bit to go till its finished, Its been welded already (it's 3 pieces, the pedal it's self, the part that goes to the master cylinder and a little spacer between the 2 pieces) I now need to bore the pivot hole and press in a bronze bush, then machine up the tip.
It wasn't easy, bending 7mm 7075 alloy is HARD!!!! But I'm really pleased with how it's come out! Its been shaped a little more than in these pics with some nice blended chamfers.
The pistons, and both slide pins are Titanium. The Banjo bolt is alloy. All new seals/rubbers and OEM pad springs etc.
Sorry for the slightly blurry pics but the light in that part of the shop is terrible and my phone just won't take a decent photo!
To finish off the front brake set up I've gone with a CR/CRF front master cylinder. (I think this is off a 2003) I wanted to go with this set up cause I can still get the rubber cover!! I've had it all vapour blasted and it's been rebuilt with a new OEM piston and seal kit, and the rubber cover of course!!
The counter sunk screws for the cap are Ti.. yeh, they were fun to make!!! (I will be replacing the cap with a billet one in due course!) All the other bolts and nuts are Ti as well. The banjo bolt is again, alloy.
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Excelent work Stevie, love this build man.
You can post pictures!
But I guess that will never happen!
The form die's, and all the prototype pedals
were made in about 4 hours in a garage,
All you big talkers show your work!
wa wa wa wa
Ha ha ha!
Newmann , yes you can grind with little gang of followers
that is all you can do!
I asked where the form die was!
But not one of you have ever made one!
please post pics of your formed bike parts
I want to see!
I started with a cardboard template to get a feel for the shape, then I made a second in thin alloy sheet, something I could actually bolt on the bike and see how it fitted. Then I programmed the outside profile on the mill, which, when your just kinda "winging it" was interesting!! Then it was onto the bender to bend and twist it into the correct shape.
I just work in a rapid prototype, repair shop, no time for writing cnc programs, we only hours to fab, finish, or repair parts
I first driiled/ then reamed the pivot holes on a flat plate, then also made a quick cardboard pattern, traced onto aluminum
cut out with band saw(5 minutes each)
Matched drilled/ reamed pivot hole thru steel blocks/ varied thickness pieces to match conture of stock pedal
mirror images of each
Machined a matching A2 pin to hold pedal cut out
inserted parts together, put in press, applied pressure/ pedal formed to exact mulitple bends(81-83 RM pedal)
lathe turmed pivot pins, .005 press , pressed in
milled pocket for tip's
machined tip, by hand on Bridgeport pressed tip on
tigged welded parts together
used a c'sunk A2 allen thru
machined a oilite frame bushing
and oring coller for the back of the mount
three pedals were made to check length,
stop height, test fit on bike , checked with
boot on to see which pedal worked the best
Going to leave the twin shocks and go Evo next year?
By the way, for those of you who don't know, Stevie can ride as well as he builds.
I'm not sure this one will be fininshed in time for me to ride it in our national series but it will be ready for the vets MXDN in september...
Thanks for the compliment, I wish it were true though! HA! I can get round the track ok.... when I've got my head on right that is!
Stevie
The rear chain guide plate was, as you can see, completely f**ked!! I spent a good few weeks looking at it and scratching my head thinking "how am I going to do this?" The double bend in it makes measuring and programing it a little difficult... I tried but I really couldn't get anything I was happy with. Then "ping" It hit me! I flattened out the bend in the vice!!
I decided not to CNC it as there are no straight edges on it so finding a datum to work from was difficult. I set to with a piercing saw, the pillar drill and some files!! I finally got to use my guitar making qualifications!!
Then I put the bends in on the sheet bender. It fitted perfectly! Once I'd vapour blasted it and given it rub over with some wire wool it looked spot on! We have a guy come and work with us part time in the evenings, he's a tool maker and there isn't a lot he can't do, (he's also a brilliant teacher and a great friend) he though I'd CNC'd it!!
To finish it off I made titanium lower screws as per the factory bike with a machined "+" in the head.
The last part to finish off the motor was the Power valve adjuster assy. Again the original was knackered. The adjuster screw needs to be hardened so its made from silver steel. (which can be hardened with a blow torch!)
The base "nut" is Titanium as is the lock nut (not pictured) these only have an M5 x 0.5mm thread in them. Tapping Titanium is hard, really hard, doing just these 2 small parts destroyed a brand new tap!
Thanks to my good friend Keith winding me up, I ended up doing stuff I really had no intention of making.
Kill switch clamp screw, the screws for the clutch lever cover all in Titanium. These are SOOOOO fiddly, they really tested my patience! The ones on the rubber cover are M3x5mm!
Obviously the pivot bolt and pinch bolts are TI aswell.
M4 carb float bowl screws.
The M5 screws for the rear brake hose guides.
Stevie
I wait updates to this thread more than to any other thread here. This is amazing work!
Pit Row
Gives us all ideas as how to go about it.
If only you guys were closer you could both mentor me hahaha !
Nice job, thanks for sharing.
Can't wait to see it finished!
You need one of these to mount over the stock plastic guide on your 86 CR. Drop me a line at keithrpalmer@yahoo.co.uk
stock
Absolutely beautiful build.
Hopefully it will be ready August-ish, in time for the VetsMXdN. I cant wait to ride it, and seeing it every day is driving me nuts but earning a living is coming first at the moment.
Stevie
Post a reply to: 1986 CR 250 RC project/rep/build up.. IT'S FINISHED!!!