|The sand casting was actually two halves that were welded together. Not a single piece as shown here.|
Saturday, October 9, 2010
Wednesday, September 1, 2010
The power transmission for the Cycleton One is contained in the rear swing arm. In this post I am going to explain as much as I can about the design and build processes without giving away the trade secret goodies. I will say; however, that the motor is a custom build from Astro Flight and I was heavily inspired by this guy's electric recumbent motor set-up.
|The three stage gear reduction system goes from the motor to a timing pulley, then through a jackshaft to the front sprocket and finally to the drive sprocket at the rear wheel.|
|The motor is fully adjustable in the mount to adjust belt tension and better alignment.|
|Several iterations of Masonite mock-ups were done to get the design right.|
|Final parts were water jet cut out of .25" aluminum and then hand milled for precision fit|
|A special jig was made to mill out press-fit bearing surfaces|
|Workin' it out|
|The focal point of the right side of the bike. I did run into some rubbing problems, but I think a smaller diameter timing pulley should rectify the situation.|
|Tank/seat half way through clay|
2. CNC the basic SolidWorks model into the clay.
3. Make changes in tape wall drawing and then on one-half of the clay.
4. Get help from Ryan Black-Macken with mirroring and adding a body line.
|Initial hand modifications|
|Part sprayed with barrier and beginning to make parting line for mold|
|How the lower fairing looked after removal from mold|
|More appropriate tank photos to come|