How To Cast Silicone Bike Bits

April 26, 2024 by Jenny List 17 Comments

It’s a sad fact of owning older machinery, that no matter how much care is lavished upon your pride and joy, the inexorable march of time takes its toll upon some of the parts. [Jason Scatena] knows this only too well, he’s got a 1976 Honda CJ360 twin, and the rubber bushes that secure its side panels are perished. New ones are hard to come by at a sensible price, so he set about casting his own in silicone.

Naturally this story is of particular interest to owners of old motorcycles, but the techniques should be worth a read to anyone, as we see how he refined his 3D printed mold design and then how he used mica powder to give the clear silicone its black colour. The final buses certainly look the part especially when fitted to the bike frame, and we hope they’ll keep those Honda side panels in place for decades to come. Where this is being written there’s a CB400F in storage, for which we’ll have to remember this project when it’s time to reactivate it.

If fettling old bikes is your thing then we hope you’re in good company here, however we’re unsure that many of you will have restored the parts bin for an entire marque.

Shôtarô Kaneda’s Motorcycle, For Real

March 17, 2024 by Jenny List 25 Comments

For fans of the iconic anime Akira, there’s only one way to traverse the mean streets of post-apocalyptic neo-Tokyo, and that’s the futuristic mount of motorcycle gang leader Shôtarô Kaneda. It’s a low-down feet-forward machine with, we’re told, “Ceramic double-rotor two-wheel drive,” which we’re guessing is some kind of hybrid electric drive with what sounds like a gas-turbine motor. Over the years, there have been a few different attempts to create a real version of Kaneda’s bike, and we’re pleased to see the latest from ヲタ工房「ポンちゃンネル」(Ota Kobo “Ponchanner”). It uses a twin-cylinder Kawasaki motor in an entirely custom-made frame, with dual single-sided swingarms front and rear and hub-centre steering.

The full build in the video below the break is pretty long but well worth a watch, and it includes a lot of very highly skilled metalwork. It’s an interesting choice not to attempt to make a direct replica of Kaneda’s bike. Still, we think some of the differences are dictated by this being very much a roadworthy and everyday-rideable machine.

Continue reading “Shôtarô Kaneda’s Motorcycle, For Real” →

Ride DIY Or Die This Badge-Less Suzuki

July 3, 2022 by Kristina Panos 12 Comments

A few years ago, [Charles] picked up a sweet Suzuki motorcycle that checked all the boxen: it was in good shape, bore a few useful upgrades and a box of spare parts, plus the price was right. Though he assumed that he had pored over every picture on the classified site before buying, it wasn’t until later that [Charles] realized that something was indeed missing from the bike — a piece of chrome that does little more than to cover the tee in the brake line and bear the Suzuki brand. Once he saw the problem, he couldn’t un-see it, you know? And at that point, he just had to have that little piece, even if he had to make it himself.

That wasn’t the original plan, of course, but bike parts are expensive to begin with and only get worse as size, condition, and rarity increase. [Charles]’ quest to find this piece was halfway successful; he found a reasonable-but-rusty facsimile of the right part, although the emblem portion was long gone. Then he remembered the wife’s vinyl cutter.

Now, let’s stop right there. If you know anything at all about these vinyl cutters, you know that they are basically glorified 2D plotters with a knife attached where a pen would be. Send it any 2D file and you’re good? No, no; of course not. These things are locked down by the manufacturers.

Fortunately, [Charles] found inkscape-silhouette, which makes light work of sending SVGs to the machine. After much back and forth and maybe a bit of coin-flipping, [Charles] settled on the classy, stylized ‘S’ version rather than the full-on Suzuki badge. We think it looks great, and we’ll never tell anyone.

While this isn’t quite the type of badge we’d normally talk about, it’s a great project nonetheless, and it’s always nice to hear about projects that open up otherwise closed-source hardware.

There’s A LEGO Suspension Dyno Now

June 16, 2022 by Lewin Day 1 Comment

When it comes to the development and testing of performance suspension, it’s helpful to have a test apparatus that lets you recreate certain conditions reliably. This LEGO suspension dyno does just that, and it’s clearly a big help for those doing R&D on minifig motorcycle suspension.

The build relies on four motors to overcome the resistance of turning a chunky conveyor belt, which acts as a rolling road. As the belt is built out of Technic beams, various LEGO blocks can be added to the conveyor to act as bumps or perturbations for testing suspension.

The video demonstrates the use of the dynamometer, showing how a simple LEGO motorbike design deals with bumps of various sizes. It’s easy to swap out forks and springs and change the geometry to tune the suspension, and the changes can be easily seen when running it through the same test conditions.

While we don’t imagine there are too many people working in this particular field, the lessons being taught here are valuable. This setup allows one to quickly visualize how changing vehicle parameters affects handling. It’s hard to imagine a better teaching tool for vehicle dynamics than something like this that lets you see directly what’s really going on!

Continue reading “There’s A LEGO Suspension Dyno Now” →

Motorcycle Regulator By Popular Demand

May 23, 2022 by Bryan Cockfield 23 Comments

A few weeks ago we posted a build of an avid motorcycle enthusiast named [fvfilippetti] who created a voltage regulator essentially from the ground up. While this was a popular build, the regulator only works for a small subset of motorcycles. This had a large number of readers clamoring for a more common three-phase regulator as well. Normally we wouldn’t expect someone to drop everything they’re doing and start working on a brand new project based on the comments here, but that’s exactly what he’s done.

It’s important to note that the solutions he has developed are currently only in the simulation phase, but they show promise in SPICE models. There are actually two schematics available for those who would like to continue his open-source project. Compared to shunt-type regulators, these have some advantages. Besides being open-source, they do not load the engine when the battery is fully charged, which improves efficiency. The only downside is that they have have added complexity as they can’t open this circuit except under specific situations, which requires a specific type of switch.

All in all, this is an excellent step on the way to a true prototype and eventual replacement of the often lackluster regulators found on motorcycles from Aprilia to Zero. We hope to see it further developed for all of the motorcycle riders out there who have been sidelined by this seemingly simple part. And if you missed it the first time around, here is the working regulator for his Bajaj NS200.

Motorcycle Voltage Regulator Uses MOSFETs

April 29, 2022 by Bryan Cockfield 34 Comments

For how common motorcycles are, the designs and parts used in them tend to vary much more wildly than in cars and trucks. Sometimes this is to the rider’s advantage, like Honda experimenting with airbags or automatic transmissions. Sometimes it’s a little more questionable, like certain American brands holding on to pushrod engine designs from the ’40s. And sometimes it’s just annoying, like the use of cheap voltage regulators that fail often and perform poorly. [fvfilippetti] was tired of dealing with this on his motorcycle, so he built a custom voltage regulator using MOSFETs instead.

Unlike a modern car alternator, which can generate usable voltage even at idle, smaller or older motorcycle alternators often can’t. Instead they rely on a simpler but less reliable regulator that is typically no more than a series of diodes, but which can only deliver energy to the electrical system while the motor is running at higher speeds. Hoping to improve on this design, [fvfilippetti] designed a switched regulator from scratch out of MOSFETs with some interesting design considerations. It is capable of taking an input voltage between 20V and 250V, and improves the ability of the motorcycle to use modern, higher-power lights and to charge devices like phones as well.

In the video below, an LED was added in the circuit to give a visual indication that the regulator is operating properly. It’s certainly a welcome build for anyone who has ever dealt with rectifier- or diode-style regulators on older bikes before. Vehicle alternators are interesting beasts in their own right, too, and they can be used for much more than running your motorcycle’s electrical system.

Continue reading “Motorcycle Voltage Regulator Uses MOSFETs” →

This Chariot Is Pulled By A Team Of Motorcycles

April 11, 2022 by Jenny List 21 Comments

We’re fans of unusual forms of transport here, so when we saw an article featuring a home-made motorcycle chariot we knew we had to share it with you. You’ll probably notice it comes from the keyboard of our colleague [Lewin Day] as he moonlights writing for The Drive, and he’s brought along a lot of context and history to the dual-Husqvarna chariot built by [Jack Field].

The machine itself is a chariot in the ancient Roman fashion, a two-wheeled platform on which the rider stands and holds the reins. Instead of a team of horses though there is the aforementioned pair of Husqvarna motorcycles, and a pair of rods to their handlebars with throttle and brake controls take the place of reins. It’s fair to say that this might not be the least hazardous of conveyances, but it appears both rideable and controllable, and will appear at motorcycle shows. truth be told we’d like to have a go ourselves, but since it’s in Australia we think there’s little chance. Unexpectedly the motorcycle chariot is not a new idea, with their being used for full-scale races back in the 1930s. There’s a trip into that world with some exciting but lethal-looking racing action to view, but it seems that these machines exist here in 2022 mostly for show.

This isn’t the first machine operated by reins we’ve brought you, how about a rein-operated tractor?