CR750 replica build

[CR21]

A few more pieces of the jigsaw for the brake plate. Control arms and cams off the machine:



Blasted:



]


Cheers,
CR21

[McCabe-Thiele (Ted)]

The time sheet showing the cost of this build will need a new term, money pit is far too derogatory.

How do you quantify a mechanical work of art like this, it's so off the scale it's almost AI.

[taysidedragon]

Fantastic!  Do you use a broaching machine to cut the internal splines?

[Laverda Dave]

Fantastic work and what a shame a lot of this will be hidden from real view.
If you were able to make 400/4 Kick Start knuckles to replace all the cracked ones out there you could possibly retire   

[taysidedragon]

Fantastic work and what a shame a lot of this will be hidden from real view.
If you were able to make 400/4 Kick Start knuckles to replace all the cracked ones out there you could possibly retire   

Thats exactly what I was thinking of Dave. Hence the splines question. 🙂

[McCabe-Thiele (Ted)]

I'm guessing a Broaching Machine is not used for making Badges or Ladies Dress Pins.

[CR21]

Ted - that would have some scary numbers on! I will keep thinking of a term 

taysidedragon & Laverda Dave - on these parts they are cut with electrical discharge machining (EDM) as I have access and it is a great process for low volumes.

I have had custom broaches made before:



Of course - 400/4 Kick Start knuckles would not be an issue - are they no longer available? Does anybody have a NOS sample to send across and I can take a look.

The rods and clevis ends are now complete, another piece of the jigsaw sorted. 



Cheers,
CR21

[taysidedragon]

The only 400f kickstart knuckle I  have is cracked and repaired.  Most of them fail in the same place where the metal is too weak. Could do with a little more meat in the weak spot. Hopefully someone can lend a precious undamaged knuckle for measurements.
Sorry for hijacking original post!

[AshimotoK0]

Some of those CNC EDM machines are mind blowing.
This one uses one of our proportional control valves /closed loop control system that I designed  for the electrode flushing with DI water.

They were in Coalville in Leicestershire but now in Shepshed.

https://winbrogroup.com/edm-300-machine-solution/


[ Guests cannot view attachments ]

[Laverda Dave]

I can send an undamaged knuckle to you if I take it off my original 400/4 for you to inspect.
Not only do they crack in the area suggested by Gareth but I think the main reason they crack is when the owner kick starts the bike but forgets to lift the footrest first. This results in the kick start lever hitting the footrest with such force it cracks the knuckle in an already weak area.
The knuckle hasn't been available for years and most used ones are cracked. If you can find an unbroken one (as I did in 2015) it cost me £80 + VAT, import duty and postage from the USA!
If you PM your address I'll send mine over after Christmas via signed for delivery as obviously I don't want it lost in the post😱.
Sorry for the hijack, back to normal service now 👍

[CR21]

AshimotoK0 - they are indeed - amazing bits of kit. It is always a bit of a kick when your design/engineering work is put into practice 

Laverda Dave - no worries drop me a PM in the new year.

Cheers
CR21

[CR21]

Arms and hardware tested for fitment - so far looking good. Tested the fitment of a NOS cable that I came across:



Also had the springs made by a local firm:



Starting to come together. Shoes being sent off for lining with a race compound.

Cheers,
CR21

[JamesH]

This is hands-down the highest quality build I've seen documented on this or any other forum. The standard of workmanship and execution is blowing my mind. Please keep the info/updates flowing - it's truly inspiring.

[Orcade-Ian]

I just love threads like this and as James has just said, the best workmanship I've seen anywhere - including the Aircraft factory where I served my apprenticeship!  The only other place that came anywhere close was my friend Jim Marland's Jaguar and Mercedes replica car company Proteus - now retired.  To turn CAD into CAM is something I'm still fascinated with.  Many thanks for sharing your work.  I thought Hawker Siddeley were at the forefront of technology but that was nearly 60 years ago!

Ian 

[Rozabikes Tim]

Yes so impressive. What a talent.

Where do we place our orders. An RC166 please.