Hybrid project

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Gerrit
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Re: Hybrid project

Post by Gerrit » Sat Sep 29, 2018 6:57 pm

With the LH spacer's width reduced to the required 10 mm I can now confirm the width of the RH spacer to be 6.3 mm and can get it made. From left to right: LH spacer, sprocket carrier bearing and spacer, LH wheel bearing, wheel bearing spacer, RH wheel bearing, spacer, vj22 RGV caliper carrier, and gap to be filled by the to be made spacer.
Note that this setup is for a vj22 RGV rear wheel, RGV 20 mm axle and vj22 RGV style caliper carrier. The dimensions quoted won't be correct for other parts.

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Gerrit
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Re: Hybrid project

Post by Gerrit » Mon Oct 08, 2018 3:05 pm

The Suzuki vj22 RGV rear caliper carrier is prevented from rotating by a tongue and groove system: a tongue milled into the carrier....

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..... which mates with a lug welded to the RH inside of the RGV swingarm (the swingarms in the pics aren't mine):

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The lug is 12 mm thick nominally and the groove 13 mm wide giving a clearance of 1 mm (rattle clearance) which seems excessive but was probaby done so that positioning of the lug during manufacture wasn't too critical. Length of the lug is 20 mm (my thanks to SP_BOTT for the dimensions) so I obtained a length of 20 x 30 mm aluminium bar and cut off a 20 mm long section. The photo shows the tongue rough cut.

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Next, my "favourite" pastime, filing the tongue to the correct size and shape..........
"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 » Thu Oct 11, 2018 3:10 pm

I haven't definitely decided yet which setup I will be using for the rear caliper assembly, but it will be either the GB Moto setup for the vj22 RGV:

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..... or the Tyga rear caliper bracket for vj22 RGV:

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...... with Brembo caliper:

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Prices including postage are currently similar. The GB Moto setup seems to be slightly lighter i.e. less unsprung weight; on the other hand, Brembo spares are most probably more easily found which is also a factor to consider.
(The RGV rear caliper bracket will be for sale once the lug has been finished and welded to the swingarm.)
"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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Posts: 249
Joined: Fri Jun 26, 2009 12:09 am
Location: Kingdom of the Netherlands

Re: Hybrid project

Post by Gerrit » Fri Oct 12, 2018 7:08 pm

Finished lug in forward position in caliper bracket:

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and in aft position:

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Finished lug, rear end rounded to match rear end of locating groove. Crossatched area shows, very roughly, area to be removed to match inside of RH swingarm leg. Final dimensions to be determined when remaining spacer for rear wheel has been made.
Vertical clearance of lug is about 0.4 mm, side clearance to be about 0.2 mm.

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"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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500bernie
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Re: Hybrid project

Post by 500bernie » Fri Oct 12, 2018 10:42 pm

Great work Gerrit 8)
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