The technical adventures of Dr_C

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By popular request (well, Bushie asked), here is a model of the café racer frame I'm going to produce!

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I'm cheering on too as others likely but shy to talk to the master.☺️. Of disaster?
 
The latest "disaster" I mastered (!) even made the big end needles stamp marks in the big end pin. I thought I had yet another pin on the shelves somewhere, but no. So I had another two pieces fabricated. The new alu parts are finally up in the CNC-machine, so there is hope for some workshop therapy during the Christmas holidays!
 

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Here we go again! New cb-housings have finally arrived! The crank cases are also machined, so these parts will just slide in. Now welding!
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I was more thorough this time with cleaning and grinding before welding. Hopefully the welds do not look, too much, like a birds crap...

Afterwards the casings were aged 24h at 100degC in the oven, spreading a "popular" scent of racing in the kitchen.
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polska said:
So is it just a matter of Assembly now?
Click to expand...
Not quite. The CB housings are welded onto the crank cases. Now they are at the machinist to get the final touch to bearing seats and sealing surfaces. After positioning, welding, ageing, the material moves around a bit. As the tolerances are of the essence, I have left about 0,5mm for the final machining on critical surfaces. Also the cover remains to be machined.

THEN, it's a matter of assembly! [emoji4]

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There's a bit of Salvador Dali about that counter balancer Dr_C!
All that local welding doesn't affect casing alignment?
 
Hi guy's,

My concern wont be the casing tolerances , but the counter shaft diameter , thinking about the force created by the outer masse at the max revs makes me worry a bit , may the shaft be hard enough not to bend , but you know what , we will see ;)

anyhow ,this is an vey nice job :)


.
 
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fdracing said:
Hi guy's,

My concern wont be the casing tolerances , but the counter shaft diameter , thinking about the force created by the outer masse at the max revs makes me worry a bit , may the shaft be hard enough not to bend , but you know what , we will see ;)

anyhow ,this is an vey nice job :)


.
Click to expand...

Thanks!
Simulations of the previous CB design showed the radial bending at 9000rpm to be 0,22mm. This time I have added 2mm on the shaft diameter. Radial clearance is appr. 1,0mm between CB and crankshaft. There was no problem with this in the last attempt.

Fingers crossed, please!
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