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Thread: Knewman's Knuckle

  1. #276
    President: Big Cat Club Array newman's Avatar
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    Quote Originally Posted by travisn View Post
    That's really good actually. The casting tools I deal with at work for low volume production are 1-2 magnitudes higher than that.
    I've found that the crossover point varies on wax print vs rapid wax mold but it's generally about 10 pcs. So if you really only need one of something then wax print is definitely the way to go.
    Icecream Paintjob

  2. #277
    President: Big Cat Club Array newman's Avatar
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    Ok, got some work done the past couple days.

    First things first I had to mount the footpegs, so I started by cutting out some Ľ 316 on the saw, then smoothing it and bending it up.







    Then I welded on some gussets:



    Then did a test fit. Seems to be going well so far…





    Then I polished them up. This video shows what they looked like after polish. https://www.instagram.com/p/BTh-Uhjl...en-by=ctnewman

    After that, I mounted the floorboards on.






    It’s shocking how skinny it is!



    Then it was time to make some brake linkage. All I used to make this was an angle grinder, a drill press and a bandsaw.







    Then I made some more pieces… here’s a bit more detail, should be pretty self explanatory.





















    Then welded those parts on a part I made on the lathe, blended the welds and polished them:





    I wanted some unique clevises, so I had to make those as well. Here’s how I did that. Turn OD



    Use grooving tool to profile



    Sand smooth



    4 pieces done



    Then put in the mill in the rotary table and slot and drill.



    The last step I didn’t take photos for, but I put the part back into the lathe and profiled the rest of it with the groover and sander. And this is how the parts looked when done and “installed”



    Then I had to make mounts for the master cylinder and the pivot linkage. I did the math to have the end result of the braking force be equal to that of my sportster, which is comfortable to me,
    based on leverage ratios, master size, caliper pot size, etc. Fab tip: it’s often helpful to fab small brackets and things while they are still attached to the stock which is helpful for clamping, drilling, sanding polishing, etc. Also, protip 2: don’t smash your thumb while changing brakepads on your car.



    Here’s a video of the actuation of the master:

    https://www.instagram.com/p/BTvYai1F...en-by=ctnewman

    After that it was time to build a front portion of the front pipe. I had a midsection cast off a 3d printed wax model, bolted that to the frame, then built a pipe from 304 using vband flanges to mount
    it. I had to make the flanges but used an off the shelf clamp.
    Here are several shots of the exhaust.















    And here’s a tool I made to make cutting tubing easier and more accurate. First, set the angle and lock it down.



    Then add the hold down ring and clamp that down. The whole plate slides in the miter groove of the saw and you get perfectly radial cuts every time.



    You need one for every CLR tube you have, and every diameter, but since I really only build Harley exhausts, I made 1.75 OD X 2,3,4,6 CLR. I need to make a 1.75CLR still.

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  3. #278
    Lifetime User Array focusinprogress's Avatar
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    that exhaust casting is fucking rad.

  4. #279
    Sr. User Array maxwell's Avatar
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    Quote Originally Posted by focusinprogress View Post
    that exhaust casting is fucking rad.
    This.

    Will it remain as it looks or be polished once the exhaust is finished?
    MAXWELL
    BLAOWW!!

  5. #280
    President: Big Cat Club Array newman's Avatar
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    Not polished. Finish as is. Might reblast it to remove the color from the welds for the vband.
    Last edited by newman; 05-08-2017 at 02:21 PM.
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  6. #281
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    Quote Originally Posted by newman View Post
    Might reblast it to remove the color from the welds for the vband.
    Leave the coloring

  7. #282
    President: Big Cat Club Array newman's Avatar
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    Made a top motor mount. Nothing fancy here. I wasn't feeling exceptionally inspired when I was designing it.







    Used 1/8 filler rod which made blending the welds a lot simpler than the welds on the foot control bracket. Also made a fixture to hold everything true because I knew I was going to be putting a lot of heat into it. It pulled a little bit, but it pulled evenly, so I will probably have to run a .030 shim behind the center bolt.



    Fit well. There will not be an issue with the rocker tins interfering...





    Then got it polished up. Polish only took 3 hours which isn't bad.







    Icecream Paintjob

  8. #283
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    Any updates?

  9. #284
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    Quote Originally Posted by Quattro Krant View Post
    Any updates?
    plenty....https://www.instagram.com/ctnewman/

  10. #285
    Mr. G Q Array Onyx Z32's Avatar
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    He's in a time crunch at the moment so going forward how much he devotes to social media will probably be limited.

  11. #286
    President: Big Cat Club Array newman's Avatar
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    Been doing a bad job of keeping the forum updated. Pretty current on Instagram though.

    Made this trans plate from 316. Since I was making it to fit the trans case I had, I was able to maintain on;y .002 clearance fit on the alignment tabs on the bottom of the transmission so the belt adjustment stays super square.





    Next I worked on some clutch linkage. All these parts are stainless and handmade, with the exception of the cone cable clamp nut. All parts have bronze bushings at pivot points. Cable rides around a pulley to actuate clutch throwout fork.

    HERES A VIDEO THAT IS PROBABLY CLEARER: https://www.instagram.com/p/BUIrD-TFTqT



















    Then I pressure tested my frame since it’s also the oil lines. No leaks! Also added two ports with supermag drain plugs in it. Here’s a video describing the oil flow path: https://www.instagram.com/p/BUXdb6elmhX



    I also had to make an NPT to banjo adapter so I started with an off the shelf fitting:



    And made it nicer:





    Next I made a kicker pedal shaft. I made it so that it folds in real far allowing me to get my foot on the pegs:







    Then I made the actual pedal out of sheet metal.





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  12. #287
    Regular User Array lorge1989's Avatar
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    How many hours per pedal? That looks absoultely insane.

    Also isn't a bad thing that when you touch the frame you will get burned because of the hot oil?

    1994 Audi 90 V8 - 1988 Audi 90 MS3X - 1978 GMC High Sierra

  13. #288
    President: Big Cat Club Array newman's Avatar
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    Quote Originally Posted by lorge1989 View Post
    How many hours per pedal? That looks absoultely insane.

    Also isn't a bad thing that when you touch the frame you will get burned because of the hot oil?
    Thanks, the pedal took about 35 hours to make.

    There are a million hot things on the motorcycle. Most will be hotter than the frame will get. It's not like you really touch the frame ever anyway.
    Last edited by newman; 05-26-2017 at 08:35 AM.
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  14. #289
    Climbin in ya window... Array travisn's Avatar
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  15. #290
    President: Big Cat Club Array newman's Avatar
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    OK. So here is the deal. It was madness trying to get the bike done before going to born free. Had first start the sunday before BF, then left monday morning. So far I have only ridden it a few hundred yards, but it works!

    The trip out took 55 hours, including an 8 hour layover at the cagney's (where most of these pictures were taken, click this link for image credits: http://imgur.com/a/WRaxl) The return trip took 47 hours with essentially zero breaks!

    Here's how it shook out.

    Thursday night spent all night trying to get Brent's knucklehead running for the PC show. He was one of the final 6 but I put running bikes before competion every time! Couldn't get it going, but I am starting to think the timing was 180 out...

    Friday night, I rode from the trailer to cooks and took people's champ! It was my first time riding the bike... on gravel. scary. Won 1000 bucks from 805 beer, a whole bunch of cool stuff from Kenny Kirk, Showclass, Sweatshop industries, ghettotooth, chopper supply co. It was stiff competition. Vintagetechnologies especially brought the heat, but all the bikes were awesome.

    The next day I rolled into the invited builders section at born free, a real honor. Got there early and rode into the show (well, just from the trailer) Lots of positive comments! Overheard some haters saying it was dumb but fuck em! That evening they announced the builder's pics. Ringo chop shop and Cheetah.4d took slots 1 and 2. Their bikes are both amazing and I suggest looking them up. I didn't place in top 3, BUT I was invited to Switzerland for the Art and Wheels Basel show, where they will fly me and my bike out next spring! I'm so excited and honored.

    On sunday, I wound up winning BEST KNUCKLEHEAD, which is incredible, Vintage Technologies won BEST SPORTSTER with his amazing backwards head ironhead chopper. Then JP Cycles caught me as I was leaving and gave me their "best bike at born free" award! Rode the knuck out of the show feeling great!

    Here's a video riding out of born free: https://www.instagram.com/p/BVzyxvUF...en-by=ctnewman

    Here's a video of the first ride, into cooks:https://www.instagram.com/p/BVssxdjl...en-by=ctnewman

    Huge thanks to everyone who voted in PC5, to showclass, my GF, everyone here who supported me, and to my painter Andy Zion, my motor work from BA Enterprises, Upholstery from Ginger @ newchurchmoto, everyone else who helped or supported me. My dad for letting me use his truck for a 5400 mile journey.

    Here are some pics, see above link for image credits:













































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  16. #291
    Sr. User Array maxwell's Avatar
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    What were the haters saying? lol
    MAXWELL
    BLAOWW!!

  17. #292
    Lifetime User Array turbo ls1 ss's Avatar
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    Nice work! I can't believe how skinny it looks from the front.
    2012 Tahoe Z71 - unmolested
    2000 Camaro SS - GT55 94 ETR-HO

  18. #293
    President: Big Cat Club Array newman's Avatar
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    Quote Originally Posted by maxwell View Post
    What were the haters saying? lol
    One good one I heard.

    "This is why you shouldn't let engineers try to build motorcycles"
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  19. #294
    Lifetime User Array focusinprogress's Avatar
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    Quote Originally Posted by newman View Post
    One good one I heard.

    "This is why you shouldn't let engineers try to build motorcycles"

    Because it comes out way too awesome and his poor ass look like a hack or a cake decorator?

    that's like saying this is why you don't let a virtuoso pick up an instrument

  20. #295
    Mr. G Q Array Onyx Z32's Avatar
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    Congrats man! You poured everything into this build and it shows

    Quote Originally Posted by turbo ls1 ss View Post
    Nice work! I can't believe how skinny it looks from the front.
    This is the thing that really stands out at first IMO. Holy shit it's like a piece of paper!

    Shipping it to Europe will be easy, just get a large flat rate envelope from the post office and be done with it, lol.

  21. #296
    President: Big Cat Club Array newman's Avatar
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    Some images of the left side by instagram user @virninja










    Icecream Paintjob

  22. #297
    I am Steve Job's Bitch Array BuickGN's Avatar
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    Amazing!! Congrats.

    Were you at Smoke and Dagger by any chance?
    Last edited by BuickGN; 07-09-2017 at 10:25 AM.

  23. #298
    Regular User Array lorge1989's Avatar
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    Great work and congrats.

    1994 Audi 90 V8 - 1988 Audi 90 MS3X - 1978 GMC High Sierra

  24. #299
    Lifetime User Array XwalkerX's Avatar
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    ............__._ . ........... '55 FLH - '90 FXHT - '72 C10______________

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