Testing a new some new animation features in Twin motion. Trying a new colour-way too, because I can. Always best to visualise a variety of ideas. Liking the hi-vis green and tan/cork leather.
Category: Surface Design
Design Freeze 01
Okay, I think this project has reached a design freeze. Or at least a freeze until all is printed out and it has passed the DVLA MSVA (Motorcycle Single Vehicle Approval). The last task was to cover cables that route from the lower battery box to the controller at the top of the frame with…
Colour break
I have been making slow progress on top panels of the xj600e. After putting together some draft surfaces I decided to try out the colour breaks on half a front panel I have proposed so far. Works very well to make the top set look less long and imposing. I think this is defo the…
B-Surfacing
#Garagelife – I have an all new respect for modellers that do B-Surface work. I have to admit that I have learnt so much about surfacing plastics working on the draft panels of my xj600e case study build in Alias. No draft angles because it is about low volume rapid production but working to tolerances when…
Voltage Aesthetic
Engine & Tank vs’ Battery/Controller & Motor For a while I have been okay with the controller cover. However lazy I am, I feel the need to try something different because it is starting to look just like a ICE bike with a fuel tank. I’m sure this is inoffensive but some exploration can’t hurt….
300mm limit?
Have just printed the first 300mm part. The mid top panel of the controller cover hit the supposed limit. However, the Ender 3 Max performed admirably. In fact looking at the gantry after completion, the printer could complete larger with ease. To speak of the fit… Excellent. Once the parts were pinned together on the…
Light visor
Taking a rest from the seat I decided to have a look at another part of the bike. I have been searching for an option for the lighting. I have taken a couple of bench marks and have even bought some items to make some physical comparisons. One design direction that I have been attracted…
Seat mock-up for upholstery v2
Have had a rethink about the seat. Needed to check it with rads… because I really want to find an upholsterer that can get clear rads as close to the 5mm used on the CAD model. I also placed the central line in the model to check that. Actually does a lot to reduce the…
Seat mock-up for upholstery
Originally I was going to make a foam mock-up of the seat as in CAD. However, I thought it would be a bit more accurate as an RP mock-up that matched the CAD model as a hard reference for the upholsterers foam. There was a strange 30mm correction to make. Which leads me to think…
Wheel covers (v2 angled) installed
Over the Christmas hols I managed to print out the angled v2 wheel covers. spent a bit of time prepping the surfaces so they match the wheel. Think the look okay. I have a couple of fitment issues but nothing that effects the performance, just tweaks. Oh well, on to the next thing! Maybe try…
Wheel covers (v2 angled)
The first version (v1) of the wheel covers had flat side. The geometry was adequate on v1. However the original design visualised an angled conical cover, so amendments need to me made to v1. On v2 print time has increased from 2hrs to 6hrs. But maybe some volume reductions in the void created by the…
Wheel covers (v1 flat)
Have spend a bit of time practicing the split part thing on the wheel covers. The first version is flat but I’ll aim to angle the surfaces on future designs so that they match the angle of the bevel on the hub motor. On the QS hub motor 35mm M4 screws are perfect to attach…
Back-top panel fitment
The print of the first part went surprisingly well. Fitment was good on the frame to my relief. I had to make pre-planned cuts to the controller cover. Plus, I needed to make changes to the seat pan to pull the surface that interacts with the panels back to give some clearance for the upholstery…
1st split panel
Back to the print… First split panel has been detailed with preliminary locator & fixing points. Yes, I need to get a load more completed. But, so chuffed to get the first one out of CAD and into the 3D printer. After looking at the model and the new part I think the only additional…
Control panel v2 installed
Long time no post. Have recently replaced the brake cables, one was too short and was twisted, think it effected brakes. Also managed to change the handlebars to the white set pictured in renderings. I have installed the v2 control panel that will accommodate the covering covers for the bike and now holds the contactor….
Switch panel v2 & cover
Have finally printed out a solid version of the switch panel and cover. Looks okay for a first bash but would like to make some amendments to some parts to increase the quality. All new part fi together perfectly. Need to find a rubber strip about 1-2mm thick to place in the channel where the…
Security
I have decided to take some measures to give the bike a small level of security by locking up the activation switches. I have designed a cam lock into the switch cover. Quite simple really and there is enough purchase at the back of the new switch panel to hold the lever securely. Ultimately this…
Details…
I think I finally feel happy with the main surfaces of the covers. However, there is a fair distance to travel still until it is ready to print unfortunately. Parts still need to be designed for functions such as airflow, movability, and fixing. First task of late has been airflow. The old design had heat…
Surface update
Have worked on some surface updates that include a load of details that aren’t so visible but are needed to make printable parts that fit to the frame securely. The surfaces are still WIP so still a shed load to finish. Main area to date have been the formation of : – The new blistered…
Control Panel v2
The first switch panel was great as a mule to test the system but it didn’t match the upper panels so it’s time to make a new design that works better with the upper panels. Once I have finished this i need to make a flip-up cover to give access to the panel and make…
Not pretty, but she’s a running
So, the basic powertrain of the battery, BMS, controller and the motor have been completed, or as much as they can be for now, and….. xj600e is alive and running under at full power of 100ah (charge socket works too). I am happy to see it finally work TBH. I had a couple of issues…
Top panel breaks
I have started to think about how to supports and breaks on the top panels in 300mm chunks. Although I’m still at very early days I thought it will be sensible to make the controller cover made from aluminium the main structural component of this assembly. The top, side, front and rear replacement panel pinning…
Cover redesign
3 issues that seem important at the moment: Access to the control panel – Currently thinking of a hatch over the control panel that hinges from the front (pivot point arrowed in red). Potentially this could be locked. Air flow to the bottom of the controller – Marked in green thinking that it would be…
300mm cuts
Have started to think about the opportunity to 3D print panels rather than metal form them. The more I think about it the more it makes sense. Plastic doesn’t conduct electricity, useful trait on an electric bike… and the production will be easier for my CAD skillset. Having had the printer for a while I…
Step back and see…
Great light today, thought it word be a good opportunity to take a step back and have a look at the old bike to observe it from a distance. Being stuck in the garage I’m often working up close and never get to see how it looks from a ‘normal’ street level perspective. Social media…
Rear light holder v1
Have had to put together a holder that bolts to the inside of the seat hoop to locate the rear brake/indicator light strip quickly. Original thought was to cut the metal seat hoop and insert the LED strip inside. But for the sake of getting the electric assembly together for the pilot build I’ll 3D…
Low res scans
Have been unhappy with the exchange between 3D CAS (Computer Aided Styling) and mock fabrication for a while. Very much so to the extent that it has caused me to be overly cautious in preceding to cutting a metal pattern. A solution to that has been to scan amendments that have been made in card….
Riser turned
Spend a but of time visualising the old model further to inspect the design at a higher resolution in motion. Looks interesting. Feel that there are some odd areas that need further resolving, but the self critique is good for progress. Still batting back and forth between cafe and riser, but leaning toward riser —…
Top cover [front]
Filled in the gap between the forks and the top panel. A colour contrast has been made between the two areas. I would like to make several front areas that reflect different function eventually. I.E. storage, extra functions, etc. But for the moment the simple vents that will let airflow under the controller, to avoid…
Fly screen
Started to look at fly screens. I mocked up a first stab in card. based on the CAS design, feel like it could do with some development though in terms of surface development. After seeing the bike naked for so long I feel that I could do with a smaller version. One that is a…
An electrifying life on two wheels... 