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Old 01-03-2013, 09:28 PM   #1
mark0ne OP
Ralle-Moto Adventure
 
Joined: Jun 2009
Location: central coast NSW
Oddometer: 112
Talking R1200GS Billet triple clamp project

THIS THREAD HAS BEEN MOVED SO I WILL PUT ORDER DETAILS HERE AND THE STORY IS BELOW.

The price of this products is $480.00 AUD including deliverey world wide.
The clamps is not only stronger but it offers 15mm more wheel clearence than the OEM clamp making it possible to use the front mudguard on the the bike with the 21" front wheel conversion.
Made from billet aluminium and annodised for surface protection.

To order please either email mark@rallemoto.com or send us a PM. All advrider.com members will be first in the list for delivery.

ORDERING IS NOW AVAILABLE ONLINE - WE ARE TAKING ORDERS NOW!

DIRECT LINK TO WEBSITE HERE > http://www.rallemoto.com/contents/en-us/d32.html



ORIGINAL STORY>>>>>>>

Hi Guys, I havent been on here in ages but in the last little while we have been getting requests to post some of our new projects and things we are working on here and some other forums so you guys have some light reading! Sice we dont really open up untill next Monday I thought I would come into work and do a few bits n peices including dropping you guys a line.

Thought some of you guys might be interested in how we (MSC Products/Ralle-Moto) develop new stuff.
I have posted this thread because we have had heaps of customers say how they would love to see a behind the seens story/blog on how some of our parts are made. I decided this would be a great part to start with because it is bike specific and this is a forum for the bikes this part is made for!

WHAT AND WHY WE ARE DOING THIS
The part I'm showing you is in development at the moment. The way this came about was one of our customers Greg (Quirky) rang and asked on the off chance if we would take a look at his bike with the 21" front wheel because there is no clearence for the tyre under the mudguard.
At the moment there is one option and it is a triple clamp/yoke but sells for $850.00 USD and then needs the same brand front mudguard which is another $225.00 USD which makes it a pretty solid investment in anyones language!!!
We decided that we would need to try and keep the OEM front guard and the price needs to be much better. We believe we will have this done, not easy but should be about half the price and use the standard mudguard with 15mm extra clearence for the wheel.

WHERE TO START
First off we get our hands on the bike which Greg kindly has loaned to us for this project. When get the bike we spend time carefully taking the front end apart, not just because we dont want to damage his bike but also because we can get a real close look and see how it all works and what clearence we have in areas. These are a big heavy bikes so working on them can be tricky and if you rush, things can be missed..... When we pull the bike down one of the major things that will be part of the installation is the ball joint removal and install. It is extremely tight in the clamp and needs some care when removing. We used a large capacity imact driver and a modified socket so we didnt need any heat and didnt scratch the front side of the OEM triple clamp.
It actually come out quite easy with the tools we used.

REMOVING THE FRONT END





TIME TO DRAW
We design everything first using a program called Solid Works a full 3D CAD package. This allows us to draw the part and check all kinds of things you cannot see without making a prototype and then cutting it up. We can cut it into peices on the screen and check things like wall thicknesses and where holes might get close to breaking out etc.

Here are some pictures of the 3D computer models




PROGRAMING THE CNC CODE
Once we are happy on the screen then the next stage is to start to create the CNC programs. This is a time consuming task and takes an experienced person to write code for this kind of part.
Writing the program is the key to everything on the finished part, if the program is not so good then the part will come out like rubbish compared with a nice program. We set toolpaths and cutter direction and the order they do their job.

Here is a pic of the machine simulation we do before putting the block in the machine.



As you can kind of see there is heaps of work in coding this program just for stage 1 has over 10 000 lines of code. Once the code is written in the CAD CAM package then we spend extra time editing and looking for any small adjustments we can make to speed up the cycle time.

MACHINING STAGE 1
Once the programs are written and edited we setup the first block of 6061 T6 billet aluminium in the Haas CNC machining centre. This takes a bit of time as all the tools need to be set up and the machine needs to be told where the block is in the machine.


Telling the machine where the 6kg block of aluminium is!


This is a mock up practice thread so we can check the thread size before we make a full clamp.
Once the machine is set up and coordinates are in the machine we can run the first program through and sometimes make some small adjustments to the program as we go.


Machine working its way through the job. It takes approx 16 different tools to cut their way through all the different parts to the program.


When the stage 1 material is cut away the clamp starts to take shape and this is where most of the bulk is removed.

I will post again soon, I have more pics and more info but today is close to done so its off to the beach!! (its a sunny 35 degreesC here! - If there are any other things you would like to know about this development then send me message and I will try and include it for you
* More to come shortly :) *

Cheers
Vaughan

mark0ne screwed with this post 02-11-2013 at 01:30 PM
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