My project (1GE)

[Speed Freak]

Possible that I also did them... I need to check

[RC45]

It is possible I got a little carried away though...

[Speed Freak]

But the nuts are not detailed... I`m missing the chamfer

Just a poor working view screenshot... No ejection pin spots.




Sometimes i thought that I`m going too much into detail...
But now I have seen that there is no thread on the grease nipple Shame on me!


Regarding crankcase - for the lower one I have the same problem as for the frame etc. regarding accuracy.
Upper case is in work, but i can`t work at home as my laptop isn`t good enough for opening the 3D scan (min. 8GB RAM).
As the workload in the company is going up after christmas holidays I guess there will not be much progress from now on.

[Speed Freak]

Last project finished...



let`s move on to the next one
Bearings are already here, some other parts will be ordered next week.

[Speed Freak]

It`s getting expensive when the weather stays that cold...

[RC45]

Very nice. Nice set of instruments there.

I would like to have some kind of accurate method for measuring hole center to center across multiple planes.

Such a bench jig would make capturing face planes of complex items much easier. At the moment I need to work from plane to plane, so any error is carried to the next plane.

Of course the projects we are undertaking are normally tackled by teams of people with 3D probes, so I suppose we are doing the best we can

[Speed Freak]

Yes, I have the same problem.
I`m doing all my work mainly with simple calipers...

On most of the parts I don`t need more accuracy as I don`t want to reproduce the parts.
If I want to do something like the rubber seals I take the parts again and measure them a bit more accurate and in the end it needs anyway 2-3 parts to try how it fits in reality.

On most parts the real dinesions can be found out by checking how the designer initially made the sketch.
Most of the RD500 might be drawn by hand or at least the designers learned how to draw it by hand.
A good designer is trying to use "full values", at least I`m trying to do it because I`m a bit old fashioned in this case
So if you do a sketch in CAD, try to rotate it around, think about how the designer made the dimensions on the drawing and in the end you will see, there is one option where every dimension is a perfect round value.

If you manage to do that you can also eliminate production tolerances which can be quite big as long as the designer considers them.

I have finally finished the air filter case today...
Can someone take me a picture and dimensions of the bolt and washer which is holding the wite bracket on the upper case?

[Smoker]

These CAD images are great for those of us trying to learn about the RZ500.

I especially like the exploded views, so I can see how the parts are assembled.

Is there any chance you'll do a CAD RZ500 engine?

[Speed Freak]

I`m planning to do more or less all parts except the fairing.
Around 30% of all part numbers are already finished, mainly chassis parts and seals at the moment.
Hope I can speed up a bit now as a lot of the engine parts are quite simple (bushes, washers, many different bolts which are more or less copy&paste parts with different length...)

Crankshaft is waiting in my garage to be disassembled for measurement (tools for disassembling and pressing it back together is also in work), upper crankcase is in work.

As already mentioned my only problem is that I have no accurate measuring method at home for big things like frame and engine cases.
A 3D scan of the most complex parts would be nice but is a bit expensive for doing it "just for fun".

[Speed Freak]

Temperature is still below -10°C...

[RC45]

LOL - temperature down, credit card spending up

[Speed Freak]

Not that bad... Temperature up - costs for tires and fuel go up...
It`s somehow giving it a balance over the year

[Speed Freak]

Again small time consuming details...

Full variable hose clamp.
If you put it into an assembly the diameter is more or less automatically adjusted to the hose diameter.



At least I have to do it only one time - all other hose clamps are now copy&paste parts with some different dimensions.

[Speed Freak]

+2°C in my garage and a friend found time to make some tools for me (simple pressing plates).

So I disassembled my 2 spare cranks.
Conrods are anyway damaged (small end bearing failed on 2) and another one has a big end bearing which was close to fail, completely blue which means it was very hot.
Don`t know what happened with this engine, got it with 2 completely destroyed cylinders.





Need to take some measurements, but as 2 big end bearings are blue I think it isn`t a good idea to even think about reusing the inner webs.

Has anyone experience with the Yambits crank webs?
Thinking about using 4 new crank webs and a set of new conrods together with new bearings (already at home).

[silverstrom]

If you decide to get rods from Yambits make sure you measure them carefully. There have been some issues with Yambits rods having external dimensions that are too big and the rods hit the cases when the crank rotates.