Hybrid project

Show us that box of bits in your shed!
Gerrit
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Re: Hybrid project

Post by Gerrit » Sat Aug 18, 2018 12:41 pm

Next job: the swingarm. I have a vj22 RGV rear wheel; this came with the axle, which is 20 mm, the KR-1S axle is 17 mm. According to my digital kitchen scales the RGV axle weighs 357 g, the KR axle 547 g. The choice is either use the KR axle and having it drilled hollow, or use the RGV axle which is already hollow. As the stiffness of a shaft increases to the fourth power with the diameter increase, I will use the RGV axle rather than having the KR part drilled. This, however, means filing the slots in the swingarm for the axle to take the larger RGV part, but this only cost my time and effort (plus rude language- I loathe filing!) whereas I have to farm out the drilling (which even at mate's rates costs Euros) as I no longer have access to a lathe. Also, the chain adjuster blocks will have to be modified to take the RGV axle, this is a job for my expandable reamers.

To paraphrase the Bangles, "File away, file away, file away....."
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Gerrit
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Re: Hybrid project

Post by Gerrit » Sun Aug 19, 2018 3:22 pm

The chain adjuster blocks now fit the RGV axle:

Image

The RGV axle is slightly longer than the 1S axle, but two M20 washers take care of the difference.
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Gerrit
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Re: Hybrid project

Post by Gerrit » Wed Aug 22, 2018 8:49 am

First step in modifying the axle slots is to mark the area around the slot with a marker pen, then add the outline of the slot's new shape (on both sides of the slot of course):

Image

Getting there. Remaining work to be done with the help of a Dremel multitool:

Image
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Re: Hybrid project

Post by dmac » Wed Aug 22, 2018 9:58 am

For someone that claims not to like filing, you are doing an awful lot of it :lol:

Keep up the good work, it's nice to see a performance build - and the differences in assemblies between manufacturers.
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Gerrit
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Re: Hybrid project

Post by Gerrit » Wed Aug 22, 2018 11:26 am

Actually, I DO loathe filing, but unfortunately it can't always be avoided.

Perhaps I should change the title of this project from "Hybrid" to "Mongrel" as it will really be a mix of stuff- KR-1frame, 1S swingarm, RGV bits, TZ pieces, ZXR odds, KX125 sods etc etc. Stir well- and hope for a good result.
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Gerrit
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Re: Hybrid project

Post by Gerrit » Tue Aug 28, 2018 4:36 pm

First slot is finished:

Image

Next step, "Repeat procedure for second slot."
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Gerrit
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Re: Hybrid project

Post by Gerrit » Fri Aug 31, 2018 11:45 am

According to my digital kitchen scales the RGV rear caliper carrier weighs 274 g, the KR caliper carrier and torque arm 774 g. Assuming the RGV and KR calipers are very similar if not identical, this gives a saving of 0.5 kg of unsprung weight.
Part of the weight difference is caused by the needle bearing setup of the KR carrier, which is not required for the RGV setup as the RGV caliper does not rotate around the axle but merely slides backwards or forwards as the chain is adjusted.
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Gerrit
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Re: Hybrid project

Post by Gerrit » Tue Sep 04, 2018 3:26 pm

Only some trimming in the corners of the RH slot to do, but otherwise the job's finished:

Image

Image
"Mine is a long and sad tale", said the mouse.
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DougB
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Re: Hybrid project

Post by DougB » Sun Sep 09, 2018 11:39 am

Nice work, good to see how it's coming long.

Gerrit
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Re: Hybrid project

Post by Gerrit » Sat Sep 15, 2018 5:59 pm

I received a set of aluminium spacers for my RGV rear wheel today.

Image

The LH spacer needs its width reduced to 10 mm, the others can be used as delivered. Once that is done I can confirm the width of the spacer between caliper carrier and swingarm, which I've calculated provisionally as 6.3 mm.
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JanBros
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Re: Hybrid project

Post by JanBros » Sun Sep 16, 2018 9:22 am

?

I have no spacer between carrier and swingarm.

http://users.telenet.be/jannemie/mijn%2 ... pacers.JPG
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Gerrit
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Re: Hybrid project

Post by Gerrit » Sun Sep 16, 2018 2:56 pm

Are you using the RGV caliper carrier or the standard KR caliper carrier and torque arm, Jan? I'm using the RGV carrier, which is 30 mm wide; the KR carrier is 41 mm.
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Re: Hybrid project

Post by JanBros » Sun Sep 16, 2018 4:18 pm

that explains the difference perfectly :lol:
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Gerrit
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Re: Hybrid project

Post by Gerrit » Tue Sep 18, 2018 9:33 pm

To replace the vj22 RGV fork yokes I obtained ZXR400L yokes. The upper yoke before.......

Image

and after modification- the ignition lock won't be needed.

Image

Image

A bush has to be made to reduce the bore for the steering stem from 25 to 18 mm.
"Mine is a long and sad tale", said the mouse.
"Indeed it is", said Alice, looking at the mouse's tail.

Gerrit
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Re: Hybrid project

Post by Gerrit » Wed Sep 19, 2018 1:40 pm

ZXR400L lower fork yoke after removing the steering stem:

Image

KR-1(S) (upper) and ZXR400L (lower) steering stems:

Image

As the ZXR stem won't fit the KR frame the KR stem will have to be fitted to the ZXR yoke instead. To accept the KR stem a bush will have to be made to take up the difference in diameters between the stems.
"Mine is a long and sad tale", said the mouse.
"Indeed it is", said Alice, looking at the mouse's tail.

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