Author Topic: '09 500AF build  (Read 146514 times)

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Offline hulkteam476

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Re: '09 500AF build
« Reply #15 on: March 28, 2013, 06:16:45 AM »
thanks!
i need to update this thread! been crazy busy with work lately and havent had much chance to work on the bike.
Hopefully getting engine mounts machined within a week so i can get all the frame welding completed finally!



Cool ... Man
I leave you a picture of foot pegs, all titanium.
Could you quantify me (as an estimate) achievement.
Same width as your foot pegs "RAPTOR TITANIUM"
with the same types of fixed as you designed mounting Honda CRF 2002/2012
If you have enough time for that ...

Offline jBernard

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Re: '09 500AF build
« Reply #16 on: March 28, 2013, 08:28:22 AM »
As soon as i get this thing finished i'm looking at getting a few parts like the peg bosses made that i did in Ti.
But since you ask about them for a CR i know they have different mounting points/design than my KX just by looking at them.

I'll have to buy some steel stock ones and re-engineer them for each Make. And hopefully they fit a fair amount of years for each model! Would be to much expense if a particular design only fit a model for a few years.

those are some great looking factory pegs! very odd though, you can see the platform is either waterjet or cnc, but i dont know how they did the spikes, because i dont see any welds visible. i dont think they CNC'd the whole thing, that would be a nightmare. my guess is that they made the base then welded a bent piece of plate with the spikes on top, then ground down the welds and polished out the heat affected zone. my guess.
'09 KX500AF - never ending project
'14 KTM 300SX

Offline jBernard

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Re: '09 500AF build
« Reply #17 on: March 28, 2013, 08:29:46 AM »
maybe i'm confused on your post now that i think about it. were you asking about the actual pegs or the peg bosses? the peg bosses hole the peg to the frame, and thats what i made, as well as the pin.

my pegs are from Raptor Titanium.
http://www.raptortitanium.com/
'09 KX500AF - never ending project
'14 KTM 300SX

Offline jBernard

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Re: '09 500AF build
« Reply #18 on: March 28, 2013, 07:20:15 PM »
figured i'd give you guys a teaser on a few pieces i'm in the near stages of completing.....


stock linkage on left!


Here's a few hints.... Its not aluminum and its 60% of the weight.
'09 KX500AF - never ending project
'14 KTM 300SX

Offline hulkteam476

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Re: '09 500AF build
« Reply #19 on: March 29, 2013, 03:30:38 AM »
please, tell me how much. For this work on the links

This will give me a base to do this in France.

for foot pegs is (CNC) full titanium the nuance you used

I like your delirium
« Last Edit: April 04, 2013, 12:10:38 AM by hulkteam476 »

Offline hulkteam476

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Re: '09 500AF build
« Reply #20 on: April 09, 2013, 07:28:31 AM »
Need know! HI, can you tell me which diameter of nozzle tungsten did you use for the different weld cords realized. thank you



whew. after a bit of a delay on the guy getting to weld the frame up, i finally got it back.
had to make a few more passes on the welds because looking back i way over engineered the yoke, wall thickness on the joints is way to thick. its .250 and should be .125 or less so it would be more visually matching the frame. but hey, this is version 1 right?  :lol:

in regards to if i'd offer some parts for sale. yes, that is something that is def on the horizon. so stay tuned on that one  :wink:

here are some crappy iphone pics right when i got it back.





« Last Edit: April 09, 2013, 07:35:16 AM by hulkteam476 »

Offline kxpegger

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Re: '09 500AF build
« Reply #21 on: April 09, 2013, 01:58:40 PM »
figured i'd give you guys a teaser on a few pieces i'm in the near stages of completing.....


stock linkage on left!


Here's a few hints.... Its not aluminum and its 60% of the weight.

Unobtainium or magnesium would be my guess!
North Las Vegas

"05" RMZ450, "08" KX500AF "11" KTM 450SX-F "12" KTM 250SX "15" KTM450SX-F

Motorrad

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Re: '09 500AF build
« Reply #22 on: April 09, 2013, 02:01:06 PM »
Scandium, or magnesium are the only two that come to my mind.
« Last Edit: April 09, 2013, 02:06:20 PM by Motorrad »

Offline jBernard

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Re: '09 500AF build
« Reply #23 on: April 09, 2013, 03:34:37 PM »
Mg, nice job  :-D
'09 KX500AF - never ending project
'14 KTM 300SX

Offline jBernard

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Re: '09 500AF build
« Reply #24 on: April 09, 2013, 03:51:12 PM »
Need know! HI, can you tell me which diameter of nozzle tungsten did you use for the different weld cords realized. thank you


I didnt weld it personally, sorry dont know the details! we had to make a root pass and 2 or 3 finish passes on the top of the yoke so the blend was better. i over-engineered the wall thickness and its beefy but leaves a bit of a gap when its butted up next to the tubing.

sorry, wish i knew more than 10 words of francais, i could speak better to you  :-D
'09 KX500AF - never ending project
'14 KTM 300SX

Offline brianjkeene

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Re: '09 500AF build
« Reply #25 on: April 10, 2013, 06:31:27 AM »
whew. after a bit of a delay on the guy getting to weld the frame up, i finally got it back.
had to make a few more passes on the welds because looking back i way over engineered the yoke, wall thickness on the joints is way to thick. its .250 and should be .125 or less so it would be more visually matching the frame. but hey, this is version 1 right?  :lol:

in regards to if i'd offer some parts for sale. yes, that is something that is def on the horizon. so stay tuned on that one  :wink:

here are some crappy iphone pics right when i got it back.







Any update as to when you will offer any of these parts for sale? specifically the Y and rails?  Thanks!

Offline hulkteam476

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Re: '09 500AF build
« Reply #26 on: April 10, 2013, 08:42:23 AM »
Can you tell me what type of mg (nuance. grade) Have you used. please Merci

you speaks only a few words in French, but you working really well with solidworks!
software created by a French company Dassault systems


Need know! HI, can you tell me which diameter of nozzle tungsten did you use for the different weld cords realized. thank you


I didnt weld it personally, sorry dont know the details! we had to make a root pass and 2 or 3 finish passes on the top of the yoke so the blend was better. i over-engineered the wall thickness and its beefy but leaves a bit of a gap when its butted up next to the tubing.

sorry, wish i knew more than 10 words of francais, i could speak better to you  :-D
« Last Edit: April 10, 2013, 08:50:30 AM by hulkteam476 »

Offline jBernard

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Re: '09 500AF build
« Reply #27 on: April 10, 2013, 10:55:37 AM »
merci, ami  :-D

alloy of Mg is AZ31
i think AZ61 is slightly higher strength, but harder to find. Then there are a few alloys like ZK60 but some cant be welded. (not that i needed it to)
for this project though, AZ31 looked fine and was easily available, so thats what i used.
'09 KX500AF - never ending project
'14 KTM 300SX

Offline jBernard

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Re: '09 500AF build
« Reply #28 on: April 12, 2013, 05:57:45 AM »
Here are some better pictures of the wheel spacers i made out of some Ti bar stock.


and since i re-did the linkage pieces, i was surprised how everything in the bushings, collars, bearings, ect is steel and how heavy it is when its all apart.
got some tricks for making that nicer, rust free, and saving tons of weight in those pieces.
here are the collars that face the outside of the bearings.
Ti, of course.

'09 KX500AF - never ending project
'14 KTM 300SX

Offline tkeen511

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Re: '09 500AF build
« Reply #29 on: April 23, 2013, 01:23:28 PM »
so any word on selling the "y" and would it work on a 250f-2502t conversion
14 250 sx, 98/14 kx 300 afc, 91 kx 500, 72 s2 350, 11 ktm 250xcw, 10 crf 250x, 97 Montesa 315r, couple other bikes