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Old 02-08-2011, 03:41 AM   #91
yamahaman OP
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Laugh making the sprocket carrier

I have been agonising over buying the sprocket carrier and I have been quoted $390 here in melbourne. Now that was full retail and I havn't begun to chase cheaper prices here in Australia and nor will I. I am sick to death of the aussie importers adding so much to there prices to the justification of "we dont have the population base to support low prices".
I priced one of these sprocket carriers in the states and they are 190 plus 45 for shipping. How can it be? especially when the dollar is the same.

So I did some home work and found out that the talon and rad hubs are made out of 6061 t6 aluminium. I went to get a quote on a piece of round 6061 bar 180 dia x 100mm long and low and behold $55.

so

We go from this to a carrier over the next week or so

So after a bit of material removed ready to drill

That is an inch and a half drill bit (38.1mm) and i have bored it out to 40mm and added the inner taper to match the angle on the inside of the fingers of the carrier.

So here they are sitting back to back and the next step is to part the excess, below the blue mark(somehow?), then machine up the face where the sprocket carrier sits and the bearing pocket on the lathe. Then hit the mill with a dividing table to make the fingers.

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Old 02-08-2011, 05:06 AM   #92
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Very nice!
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Old 02-08-2011, 05:17 AM   #93
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Old 02-08-2011, 06:10 AM   #94
LukasM
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Holy shit. Talk about ground up build, machining your own sprocket carrier!

Watching for more.
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Old 02-10-2011, 01:22 AM   #95
yamahaman OP
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Laugh Nearly finished

So I cut the excess off and machined the face off.


What a mess I have taken everything off the outside and created the profile that I am happy with.


Now I am ready to bore the bearing pocket. I have pushed the bearings out of the carrier I am copying so I can measure the bearing pocket I have measured a very slight interference fit of .04 mm to I am going to hit the books to check how much of a fit this is because I have only got one chance to do this and I dont want to mess it up. After I bore the bearing pocket, do a test fitting of the bearings, I have an appointment with the mill and indexing table to make the fingers, drill the bolt holes and remove some material from the sprocket flange so I can fit a stealth sprocket (It has six rivets on it which need some clearance holes/grooves)

You wont be able to see it but I have made this carrier to Fit a yz/wr sprocket which has a larger PCD and a larger inner circle. I have done this so I can swap them between all of our bikes.

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Old 02-10-2011, 01:05 PM   #96
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Awesome work, no really
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Old 02-15-2011, 03:09 AM   #97
yamahaman OP
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Laugh another night in the machine shop

I had another night in the machine shop on the mill and I have done the easy part of the milling.


Here I am getting the mill ready to drill the bolt holes for the sprocket. Set the indexing head up and now checking the slot drill with the sprocket holes to make sure the first one lines up and then the rest will follow on with the indexing head.

Now I am putting groove's in to reduce weight and to allow for the stealth sprocket rivet's to fit in as I think they are the best sprockets on the market.

Here is the alignment with the hub ready for the fingers to be milled out.


Here is the front and back of the sprocket carrier. There is one last job and that is to mill the fingers in the back of the carrier and fit the bearings and seals, all finished soon.

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Old 02-15-2011, 04:15 AM   #98
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Great work on the pre-cnc M/C tools. You are probably aware that there'd be a small business opportunity if you could churn these out at the right price. I'd be up for 2.
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Old 02-15-2011, 05:07 AM   #99
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Damn fine work!!!
Wish I had some CNC machines. I've got a tonne of thing I'd like to make
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Old 02-15-2011, 10:11 AM   #100
LukasM
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Should be pretty bomb proof!

How much does it weigh compared to stock? If you want some inspiration on how to lighten it further, I've got a CNC'd KTM sprocket carrier made by Haan Wheels I could post some pictures of next week.

Lukas
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Old 02-15-2011, 10:55 PM   #101
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Thumb

That's a beauty.
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Old 02-15-2011, 11:31 PM   #102
yamahaman OP
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Thumb measurements would be better

Quote:
Originally Posted by LukasM View Post
Should be pretty bomb proof!

How much does it weigh compared to stock? If you want some inspiration on how to lighten it further, I've got a CNC'd KTM sprocket carrier made by Haan Wheels I could post some pictures of next week.

Lukas
that would be awsome I have got some pictures of the rad sprocket carrier

http://www.radmfg.com/Cush-Series-RE...radh-eq-1r.htm (all pictures copyrighted so you will have to check out this web site)

If you could include some mesurements that would be great

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Old 02-16-2011, 02:00 AM   #103
LukasM
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Quote:
Originally Posted by yamahaman View Post
that would be awsome I have got some pictures of the rad sprocket carrier

http://www.radmfg.com/Cush-Series-RE...radh-eq-1r.htm (all pictures copyrighted so you will have to check out this web site)

If you could include some mesurements that would be great

I've got a RAD carrier too, but it's for a 950/990 so the measurements are probably a bit different. The Haan Wheels one is machined with much more detail, so it's a lot lighter. I have never heard of one breaking either, even running them on 70HP big bore LC4 supermotos on slicks.

I'll get you some pics of it next week, then you can tell me which measurements you need. Here are some of the RAD carrier:



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Old 02-17-2011, 02:32 AM   #104
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nice work
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Old 02-28-2011, 04:19 AM   #105
yamahaman OP
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Laugh finished sprocket carrier



So here we have an action shot on the rotary table, on the mill, having its fingers cut into it.



And this is the finished product about to come off the bench to be de-burred. I put the carrier into a hub and its a snug fit but it works well. I prefered a slightly tighter fit to take into allowance for worn rubbers. I actually have a set of worn cush rubbers (still very servicable, from the wheel I copied) and they are not as tight but still firm to fit so I am very happy, and all this first hit I didnt have to have a second go at the sprocket carrier, all of my measurements worked well. I am quite pleased with the out come.

Sorry about the crappy phone pictures I think you guys/girls get the idea.

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yamahaman screwed with this post 02-28-2011 at 04:22 AM Reason: spelling and grammer
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