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Old 05-23-2011, 08:12 AM   #826
Poolside OP
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Originally Posted by JimVonBaden View Post

How about a PVC tubing cutter?



Might be the soft plastic will deform too much, but maybe not. Definitely a burr free cut.
Another good idea. An anvil cut, similar to the PVC cutter, was my initial plan. But unfortunately it just deforms the plastic and the cut walks. Boooo!

The cut must deform the plastic because no material is being removed, and the blade takes up space. Look closely at how un-square and un-flat the cut edge of a PVC pipe is. Sure you can get lucky and hold the cutter juuuuust right and get a pretty square cut once in a while. This has got to be repeatable.

We went the flames and knives method. It does a good job and there's no need to deburr the cut. Thanks just the same for your ideas everyone!


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Old 05-23-2011, 08:38 AM   #827
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Good for you. I only posted cause I don't want you guys hung up. Glad to hear your moving forward again. I want my part. I rode my buddies 06 multistrada with new pipe and chip work. It was definitely better accelerating than my 1150gsa (although it is much less mass than my bulky GSA). I want more peppiness. I don't have to have just as quick, just want to close up the gap.
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Old 05-23-2011, 11:05 AM   #828
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Do you have a buddy the builds homebuilt airplanes? You can try a hotwire rig they use for cutting and shaping the foam core. That might work with your jig, just hot wire the bottom off nice and flush!
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Old 05-23-2011, 02:59 PM   #829
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Hot wire cutters are dead easy to rig, all you need is a method to pull the wire tight, and a means to regulate the power, as someone mentioned if you know a R/C home-builder, you can probably borrow it ready-built.

I would use a rotary cutter though. My wife has one in her quilting tackle, when I was building planes it regularly made midnight trips to my shop for cutting mylar covering.

Like this:http://www.olfa.com/RotaryCuttersDetail.aspx?C=20&Id=70

Hellaciously sharp, and with your jig, I would think would make a very nice job of the cut for $15.00 or so.
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Old 05-23-2011, 06:06 PM   #830
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Thanks again for your ideas everyone. If these IICE Airs do get built again, many of the assembly processes will benefit from retooling. Or at least a retool of optimistic estimates Seriously though, to make one or two of something, like a hobby item for example, it's easy to invest hours in the build process. Acourse to build 100-plus of something, that's a different story.

Electrically it was easy. Mechanically, that was the problem. You know, it's a complex set of mechanical specs. Part of the shape needs to be exposed to the air, and another part must be watertight. The watertight portion needs to be easy-open with a durable seal mechanism. And whatever you two geniuses come up with for an adjustment mechanism, it must fit inside the watertight portion. Oh yes, you must use a very small standard enclosure, with a mounting flange(s) for zip ties.

Somehow it all got figured out. Only now I have to build it.

You should have heard JJ and me talking at the beginning of this project, and all along during the process. Talk was rife with things like "it'll be easy", "we'll just...", "no problem", and the dreaded "I'll cross that bridge when I come to it." That one is a killer.


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Old 05-24-2011, 06:21 AM   #831
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Assembly report.

As promised, flames and knives.



Makes a nice cut.



A real nice cut.



I did a little assembly marathon today, and my hands hurt! I'll check in later.


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Old 05-24-2011, 06:48 AM   #832
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Great job on the cut. Now take some advil and get back to work!
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Old 05-24-2011, 06:55 AM   #833
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...and the dreaded "I'll cross that bridge when I come to it." That one is a killer.

The killer one is "I'll drive off that bridge when I come to it"

Can't wait for the finished producto
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Old 05-24-2011, 03:04 PM   #834
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Assembly report.

As promised, flames and knives.



Makes a nice cut.



A real nice cut.



I did a little assembly marathon today, and my hands hurt! I'll check in later.

All ya had to add was guns and it would have been a party Need me to come help ya...I am a first rate fabricator of the official Redneck School
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Old 05-26-2011, 05:16 PM   #835
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Great job on the cut. Now take some advil and get back to work!
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Old 05-26-2011, 05:25 PM   #836
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I did a little assembly marathon today, and my hands hurt! I'll check in later.

HR has been flooded by complaints followed by claims to the insurance company for disability.

Oh, wait...
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Old 05-30-2011, 07:14 AM   #837
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Assembly report.

I'm about 1/3 of the way done with the done-as-a-full-batch processing. Many of the remaining steps are done in small batches of five or so. The units will be shipped in medium-sized batches as they are finished, maybe 20 at a time. I'll be working on them later this afternoon. And I'm going to try and take one unit the rest of the way through the assembly steps to the last step, partial encapsulation in epoxy. That's the most important step and I need to verify the encapsulation process goes smoothly.

Enjoy your Memorial Day. Cheers!



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Old 05-30-2011, 08:32 AM   #838
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Hey, I'm planning to trade my GS for an R1100S. Will the contraption still work?
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Old 05-30-2011, 08:56 AM   #839
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Hey, I'm planning to trade my GS for an R1100S. Will the contraption still work?
Yes it will work
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Old 05-30-2011, 01:47 PM   #840
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You can get a hot knife blade for a soldering gun.
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