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Old 03-28-2011, 04:52 PM   #31
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What I've just posted pictures of it not the finished part though. It's just the plug for the inside half of the mold. The outer part of the handguard that you can see is just a rough layup. The finished parts will look much nicer. We're going to use a 3D scanner to import that part into SolidWorks, where I'm going to tweak the design a little bit more. Want to add a radius to the back edge of the lower part of the handguard, as well as some recessed contour lines, recessed mounting holes for the handguard mounting hardware, etc. Will also be able to mirror this part in SolidWorks to create an identical CAD model of the left handguard. Then we're going to use a 3D printer to make plastic parts that will be used as plugs to create the molds for these handguards. That's where my work ends and my brother Robo will take over.
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Old 03-28-2011, 05:05 PM   #32
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Fantastic work and write up!!!! What sort of scanner do you use?
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Old 03-28-2011, 06:06 PM   #33
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Thanks. Don't have our own scanner, so we have to pay to have things scanned. Rob's going to handle that up in Chico, so I'm not sure.
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Old 03-28-2011, 07:19 PM   #34
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jesse, everything you do over here or on pirate is badass. carry on, if you ever make it to NW montana beers are on me. flipoff2:
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Old 03-28-2011, 10:46 PM   #35
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Thanks, and Montana's on the list, right after Idaho.
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Old 07-05-2011, 08:59 AM   #36
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Very nice indeed....... Lot`s of determination here...... Awesome.....

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Old 07-05-2011, 12:13 PM   #37
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Hi Erling. Am actually out in CO right now, going to be road-tripping through NM all this week. Never been there before.

Robo-Boogie and I spent some time looking into 3D scanners and I think we're going to get one of those NextEngine scanners, but they cost about S4000, so we just sent that handguard out to be scanned. Will post some updates when I get the files back and start messing with the CAD models. Robo has been working on some other cool composite projects too...
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Old 10-28-2011, 01:22 AM   #38
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Started working on a new project. Shaping a gas tank right now, using sheet metal to create ribs that I'll use as guidelines to maintain symmetry. Decided to try 4lb foam this time because I thought the 2lb foam I used for the hand guards was too soft.

Hey Erling, question for you: How should I go about making a filler neck for this thing? Can cut something out of an old tank or have a new filler-neck made to install now and make the filler neck part of the mold. Or I could have an aluminum filler necks machined and try to bond those to the tank? What's the best way to do something like this? And on a related note, what about threaded inserts for the petcock and mounting points?





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Old 11-28-2011, 11:38 PM   #39
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Have made a bit more progress on this tank, and have started a new build-thread about these bikes.
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Old 12-06-2011, 03:16 PM   #40
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Was just updating my portfolio and realized I've got a few more pics to share. So here are a couple of screen-captures to show what the laser-scanned hand guards look like. Going to make a couple of small design changes/tweaks, then mirror this part to make the left-side, so we'll have two perfectly symmetrical hand guard shields. After that's all done, we'll have these molds rapid-prototyped (made out of plastic) and then we'll use those plastic parts to make aluminum molds. Shaping the first hand guard shield was pretty easy. Making a second one to match the first would have been much more time-consuming. Funny because with most of my other projects, it's usually the other way around.



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Old 12-06-2011, 03:31 PM   #41
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Wow, nice work there!
I am planning on doing some composite work myself soon (rallye bashplate and fairing). Looks like I can find plenty of handy advice here then.

I'll post some pics of the bashplate mould I've made so far so you can tell me what you think of it...
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Old 12-06-2011, 03:46 PM   #42
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Thanks, but the most help I can give you is to point you to the index of helpful info that I compiled in the first post of this thread. This stuff is all new to me too. But yeah, post some pics! Was hoping that more people would jump-in here...
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Old 12-06-2011, 06:54 PM   #43
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Here you go:



My attempt at a composite bashplate.
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Old 12-08-2011, 12:20 PM   #44
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Great insight into how to make your own stuff. Ive been toying with the idea of making a bash plate and handguards for my xr600. Ill definately be doing it now. Just not sure where to get supplies for that kind of thing over here in the uk. Looks like ill be doing some google searching. Again thanks for the info and photos
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Old 12-08-2011, 12:28 PM   #45
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Quote:
Originally Posted by michael1968 View Post
My attempt at a composite bashplate.
That looks like it turned out great. Dig the reinforcing ribs/crossbracing on the bottom. Have you posted anyhing about building that before? Just looks like something I remember reading about when I was first getting into all this stuff.
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