RZ350 Super Motard

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JonW
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Re: RZ350 Super Motard

#871 Post by JonW » Mon Feb 13, 2017 8:26 am

Im with you, i meant in this instance obviously, it would be hard to find something to work with the frame as well as the OEM tips :)
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Smoker
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Re: RZ350 Super Motard

#872 Post by Smoker » Wed Feb 15, 2017 5:54 pm

First prototype is just to get the hole centers correct.

Failed on this piece.

Working on another one.

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Re: RZ350 Super Motard

#873 Post by Smoker » Wed Feb 22, 2017 3:24 pm

Second prototype adapter bolts in, but is too tall.

Gonna shave it down 2mm and see where it's at.

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Nobody noticed the new white plastic. :smt003

Decided on gold titanium nitride coating for the exhaust tips.

Will give a nice splash of gold to the tail.
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Re: RZ350 Super Motard

#874 Post by Smoker » Sat Feb 25, 2017 6:29 am

Cut down the 2nd aluminum adapter 2mm and gave it a try.

Close, but will need to cut new tubes to fit perfectly.

I went ahead and secured the exhaust tips.

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Not happy.

I left a one-finger space between the exhaust tips and the plastic - but it's too much. Now moving the exhaust tips as close as I can to the tail.
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Re: RZ350 Super Motard

#875 Post by Smoker » Thu Mar 02, 2017 6:33 am

Well, you can see the adapter is getting smaller.

Image

Took off another 5mm. Total 7mm.

Gonna try to take off another 5mm, but it might be too much.
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Re: RZ350 Super Motard

#876 Post by Smoker » Thu Mar 09, 2017 3:42 pm

Yep, another 5mm was too much. Basically, starting over.

Need to make another adapter anyway, because I want to move the holes.

As is, the exhaust tips are close to being flush with the tail plastic. But, I want the tips to stick out some more. So, need to move the holes. Will also need to cut new tubes with different angles.

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Re: RZ350 Super Motard

#877 Post by Smoker » Sun Mar 19, 2017 12:22 pm

Latest version of the test adapter.

Only has an exhaust tip hole on one side, so I have more options.

Exhaust tip position looks pretty good. Will need to cut new tubes.

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Now drawing something sexy to cut from titanium.
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Re: RZ350 Super Motard

#878 Post by Smoker » Thu Mar 23, 2017 2:45 pm

Machinist was going to order the titanium from McMaster-Carr. I know they're expensive, so I got the titanium myself.

3/4" x 3/4" x 12"

McMaster-Carr price = $169.35 usd

Tiger Metals price = $44.00 usd

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RuZty
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Re: RZ350 Super Motard

#879 Post by RuZty » Thu Mar 23, 2017 3:12 pm

Did you consider a piece of flat bar bent to the right shape? It would be a lot lighter than machining out of solid. You could also make new brackets to weld to the mufflers that go to the holes you have in your frame instead of adapting the existing ones, except then you would have to replate them, assuming they are chromed.

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Re: RZ350 Super Motard

#880 Post by Smoker » Fri Mar 24, 2017 5:22 am

RuZty wrote:Did you consider a piece of flat bar bent to the right shape? It would be a lot lighter than machining out of solid. You could also make new brackets to weld to the mufflers that go to the holes you have in your frame instead of adapting the existing ones, except then you would have to replate them, assuming they are chromed.
Yes, your way would definitely be lighter.

Adapting the existing brackets is part of the challenge.

No way a flat bar will be as cool as the machined piece I drew up.

No chrome, just polished stainless.

If I had your skills, I could have CAD drawn a much nicer piece. [smilie=dunno.gif]

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Re: RZ350 Super Motard

#881 Post by Smoker » Sun Mar 26, 2017 2:26 pm

Need a filler, cap and vent for the fuel tank.

Want this, but can't find it anywhere. Will probably have to special order.

It's small. O.D. is 80mm.

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Re: RZ350 Super Motard

#882 Post by MK » Mon Mar 27, 2017 3:09 pm

I use those for my DIY aluminum tanks, but they have no vent.
Here's some detail pics of the weld-in type.
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Re: RZ350 Super Motard

#883 Post by Smoker » Tue Mar 28, 2017 12:58 am

MK wrote:I use those for my DIY aluminum tanks, but they have no vent.
Here's some detail pics of the weld-in type.
Yeah, I'll need to weld in a vent bung.

The plastic OEM fuel tank just won't do. Not using the OEM radiators or fuel pump, so it won't look right.

There's an aftermarket aluminum SXV tank. I checked it to see if it could be modded, but I don't think it would work out well.

So, it looks like I need a full custom tank. And no ordinary aluminum tank.

First, the tank will be all flat pieces with straight edges. The only curves are on the fuel filler. The tank is sandwiched between the frame and the seat, and the seat attaches to the tank. The tank also needs extra aluminum pieces on the sides to fill in the bodywork.

I have a vague idea of what the tank should look like. I'll probably need to mock it up with cardboard, just to get a better idea of how it should go together. The tank will be naked aluminum with the welds showing.

I'm not confident at all about constructing this tank. Here's a previous photoshop of an aluminum SXV tank. Not exactly what I want, but sort-of.

Image
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Re: RZ350 Super Motard

#884 Post by MK » Tue Mar 28, 2017 3:01 pm

A tank made of mainly flat sheet parts is a piece of cake. As you described you can design it in cardboard and then just transfer to aluminum sheet.
Get 2mm Al99.5 material and use the same rods for welding.

This is what I build years ago as a kind of feasibility study (basically one of my first aluminum welding projects). It saved about 2 kg compared to the RGV tank.
(just wanted to check if I could weld a tank that wouldn't leak - still use it on my race bike)

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Re: RZ350 Super Motard

#885 Post by pscook » Wed Mar 29, 2017 10:37 am

Smoker wrote:
MK wrote:I use those for my DIY aluminum tanks, but they have no vent.
Here's some detail pics of the weld-in type.
Yeah, I'll need to weld in a vent bung.

The plastic OEM fuel tank just won't do. Not using the OEM radiators or fuel pump, so it won't look right.

There's an aftermarket aluminum SXV tank. I checked it to see if it could be modded, but I don't think it would work out well.

So, it looks like I need a full custom tank. And no ordinary aluminum tank.

First, the tank will be all flat pieces with straight edges. The only curves are on the fuel filler. The tank is sandwiched between the frame and the seat, and the seat attaches to the tank. The tank also needs extra aluminum pieces on the sides to fill in the bodywork.

I have a vague idea of what the tank should look like. I'll probably need to mock it up with cardboard, just to get a better idea of how it should go together. The tank will be naked aluminum with the welds showing.

I'm not confident at all about constructing this tank. Here's a previous photoshop of an aluminum SXV tank. Not exactly what I want, but sort-of.

Image
Two words:
Carbon
Fiber

I'm sure you can get someone to help out with a CF tank, especially if you have it mocked up in cardboard. Building a mold isn't too difficult if you are willing to build from scratch to begin with. You are effectively building a plug anyway, then a mold off the plug, and Bob's your uncle. I am certain that there are folks in your neck of the woods who would be willing to help, as I believe you are in So Cal and that area is a hotbed of Aerospace, which is cutting edge with CF parts these days. Plus all of the race shops in that area probably have lots of experience with these types of things. Heck, you could probably have a mold 3d printed off of a cardboard mockup (might cost a pretty penny), and just knock something out over the weekend. :)

On further thought, you might be able to build a mockup, make it "X" dimensions smaller, and use that as your tank plug. Build it in two pieces, join them, and line it for fuel use. Hey presto, fuel tank!
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