TRX250R.ORG
Workshop => Engine and Bottom End => Topic started by: zedicus on May 24, 2019, 10:57:22 AM
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this is a side project i have been working on for years, i have in the past produced a ton of 250R parts myself and also had 2 other manufactures make parts of my design. from air box removal brackets to aluminum intake manifolds, tie rods and motor mounts, exhaust flanges etc. i have started on the designs for billet case halves and there would be optional features you could choose for cylinder mounts. say you wanted to use a cr500 jug for a lower cost 500cc build.
it looks like 1500$ for a bare block of metal for a case half, and i still have a bit of design investment but i am sure i would cover that, so essentially the case halves would be for sale at cost of time and materials. (ball park of 4000$ full set, with a small discount on standard trx250r jug pattern probably)
there is no real benefit to billet cases over cast and finish machined. unless you did want to run a cr500 or polaris 400 top end, but with the sphynx and sabertooth and pro-x stuff all still relatively available there is not much of a need for that customization work either. the other benefit is that i could do a run of 10 sets instead of 100 or more like the casting manufactures want to do. so i can reproduce them with a smaller initial investment.
my question is are these viable yet or is there still enough aftermarket that billet cases are not needed? (i have been out of the loop a while working on other projects, your input is highly appreciated.)
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It would be awesome to see some billet blocks. I can't say I would personally be in the market for them, but I bet some duners and drag racers would be.
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Nice to see others stepping up. There are options available. ESR has made new casting halves. Panthera makes cases for their CR500 engine. Needing billet cases for the 250r, would probably be a small group. At those prices, most of us will improvise. This is just one guys opinion. How about making some all aluminum heel guards? There is a definite market for those.
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not to get off the subject but do you mind sharing some of your previously made R parts?
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i think i have an unfinished intake and maybe a exhaust flange left from the last run of things. i will see what is laying around and post something.
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(http://i66.tinypic.com/2yuelad.jpg)
Last step is done with hand held power tools, like finish porting or polishing, etc. Tie rod, intake, exhaust.
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there are enough used oem, NOS, and take out oem that billet cases aren't needed at the moment. Mat'l, design time (reverse engineering) and machining a part such as billet cases isn't going to be a big seller at the price points you mention. I'm sure a few would sell but not many.
used oem (damaged cases) are being repaired by Rob Selvy, Dave Moore and Pete (Hybrid).....and I'm sure many more. Dave Moore is dedicating shop equipment just for cases repair.
Joe
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Ya I don't want to be a buzzkill, as I'm sure the billet cases you would produce would be stellar. But it sounds like one of those situation where people would be all over it, then you'd go through the trouble of making everything, and people would crap out at the end.
There's enough out there right now where case halves aren't at a crisis status. And it sounds like ESR will be producing their cases again in the near future.
Now if you could come up with a high quality cast option, and compete with ESR that would be great. More competition the better.
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billet quick change clutch cover? or maybe the rings and the cover so stock covers can be made into quick change covers?
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when i looked into doing cast cases they needed me to order 100 or more of each side and then i would need to finish machine them. that is out of my investment range.
i could do quick change rings and covers i am sure. maybe even a full clutch cover, i will look into that.
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Yes the parts to make QC covers would be good
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I would be very interested in the qc parts!
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i think i could use standard flat stock aluminum plate and have them cut the rings and cover on the CNC plasma cutter. they would not be as fancy as actual billet parts but it would be just as strong and 1/3rd the cost. is their an argument against doing that or is this a 'BILLET OR BUST' part?
to make it a little fancier the top cover could be cut out of diamond plate.
thoughts or concerns?
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would you be using at least 1/2" material? they need to be threaded, or have inserts to accept the cover. tolerance might also need to be considered, since a stock cover will need to be modded to receive the parts.
just a couple thoughts.
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it would probably be 1/2" for the ring and 1/4" for the cover. a machined edge on the ring for welding to the clutch cover. and then tapered head bolts and machined receivers on the quick change cover. i will try to build a bill of materials out and start working on cost and retail pricing next week.
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the thought came to my mind to just make a weld on ring that the CR250 top cover could bolt too. i am going to explore that idea also.
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a weld-less solution would be great.
any aircraft industry guys out there can can offer some insight into those high temp aircraft aluminum adhesives?
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i found a junk clutch cover to measure and start working on. we shall see what creativity hits me.
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the thought came to my mind to just make a weld on ring that the CR250 top cover could bolt too. i am going to explore that idea also.
The CR cover is a cool idea but without the recess for the kicker knuckle it might be hard to adapt for use on a forward kick engine.