The original suspension is finally mocked-up in CAD and positioned correctly to ensure the new body designs do not interfere with the working mechanics. That is all.
Category: xj600e
xj600e: GOM scan
Ryan at the NTDC worked his GOM magic on the chopped xj600. After I cleaned up the file I managed to crunch it down to about 500mb. This is about 10 time bigger than the artistic scan but the detail on this scan is fantastic. This is definitely one of the most accurate scans I’m…
XJ600e: GOM Scan prep
Okay XJ600e is up on the plate for a GOM triple scan. This high end metrology system is as accurate as needed. Even with uncertainties of human operation apparently it will visually measure surfaces within accuracy levels of 10 microns. Had a couple of queries about the density of the reference dots but having seen…
XJ600e: Sketch surface v2
The design of the XJ600e sketch has seen updates. However much still needs to be resolved for this single designs. Looking forward to seeing more focused designs. It would be good to this in different formats. Proposals for the X, Y, Z generation will be v-interesting.
XJ600e mixed reality set-up
XJ600e is prepared for mixed reality development in the NTDC, a place where it is finding a new home for the moment while the research design phase is executed. The frame chassis has been secured temporally on a 500kg lift and is stable enough to hold in addition a rider, and dense foam milled from…
XJ600e: Scan day, yay!
https://youtu.be/lT8ZJ9caWs0 Finally managed to get the bike in the workshop to get some 3D photogrammetry for CAD development. The addition of primer worked a treat. The camera picked up the tubes and detail. Just some stitching from the marvelous Mr. Perkins and all will be good. Sure the students will appreciate this so they can…
XJ600e: Primed for scan
The frame has been matt grey primed for a scan because previously the cameras had trouble picking up the surfaces well due to reflections. Although this is an un-etched coat to make removal easy I like the look of it in a lighter matt colour. However, it is not for me to make such decisions……
XJ600e: Rolling chassis weigh in
Have had to weigh in all the parts in the rolling chassis to help make calculations for the powertrain: 7.1kg – 2 Forks 3.3kg – Triple tree (top & bottom yoke) 3.8kg – Rear shock 2.6kg – Front brake and handle bars (lever, calliper, and reservoir inc.) 6.5kg – Swingarm and pivot bolt 12.5kg –…
XJ600e: Battery spec
Had a very interesting day at work. Michael Apicella, a doctoral researcher in electrification, met with me to discuss the pros and cons of different battery options. Michael works in the Universities Future Vehicle Labs that develop hydrogen fuel cell cars. He is also a big fan if motorbikes. Considering various attributes: 350kg estimated total…
XJ600e: New front end
Have had a couple of matching issues with the forks. To make the old set work I would have had to make a collar and extend the thread on the stem of the bottom yoke or the triple tree. So instead of trying to force parts together I dropped into Flying Colours and did a…
XJ600e: Integrated body?
Tried a design that integrates the tank and side farings together. Looks interesting. bit more mordern. Is this what I want. dunno. Will sleep on it. Zzzzzzz!
XJ600e: Knee scoops
Had a quick go at a loose human occupant package. 97.5 male %ile manikin and xj600 bike are to scale. When laid over a sketch it would seem that I am on the dot for the scoops at the moment when it is positioned in line with the intersection of bars that are normally under…
XJ600e: v2 front end & side
Started to think about body work at the side and front end. Knee scallops need refining. Really need to do a package to see where knees actually sit on 95th %ile male. Saw some leaf batteries in a e-motorbike and they looked wide so pushed out the body work to see what it would look…
XJ600e: Contours & details
Need to start thinking about surface contours for knees, air outlets for front intake (presuming batteries produce some heat) and to create more interest in places. Just doodling. Need to start sketching in perspective to get a better feeling for the forms. Preferring shorter seat and gap between tank, may continue with these features.
XJ600e: V2 stance
Pulled an underlay from the last photo of the frame to sketch on top of to help see if all is going in the right direction aesthetically. I like the lower rear wheel but feel either front drops of the rear needs pushing up slightly as it looks like it is squatting slightly at the…
XJ600e: Dry run assembly
After chasing around for parts I thought it best to check that all the parts to date kinda fit together as Zed Parts were close to finishing the frame strip. have had some problems with the forks but have managed to kinda resolve that today. Have got some 40mm xj600 forks (previously I has some…
XJ600e: Triple tree head
Got a triple tree from Flying Colours. The guys at Zed Parts gave it a strip and de-rust and it was just a case of cleaning off the flash with a wire brush. It has a couple of war wounds but I don’t mind those as there are no structural defects. Just need to get…
XJ600e: Wheels
Got a nice eBay deal on some Original Pre-diversion wheels to set up the stance. Took a bit of cleaning up but after some wash down with a soapy jet wash and a wire brush they look pretty clean. Will probably keep the front and cover the spokes. If I eventually opt for a hub…
XJ600e: Showa shock
Grabbed a Showa rear shock from flying colours. The length matched the original. however the bushes were slightly smaller. Will have to get new bolts or bushes… or both. Spring looks a bit scuffed too. will eventually refurbish these. Oh well, onward brave soldiers eh.
XJ600e: Factory wheel sizes
Aiming to start setting up the rolling chassis for the xj600. Factory sizes for the pre-diversion wheel are: – Front: MT 2.15×18″ – Rear: MT 2.50×18″ Just need some 18″ enduro tyres now 🙂
XJ600e: Scan 01
Took the XJ600 frame into the workshop for a scan today. Metallic objects reflect the cameras so it is possible to get a better scan if painted. So off to Zed-parts it goes for a chemical dip to strip it down to metal and then to the body shop for a quick coat of primer.
XJ600e: Frame & Suspension (Haynes)
Decided to scan the usable pages just in case the book becomes damaged of I need to access it online while off-site. Currently managing the rear swing arm, forks, yokes, barrel bearings, and rear strut so I have scanned these pages and have popped it onto a PDF: frame and suspension pages
XJ600e: Shorter tank
Experimented with a shorter tank in sketchwork to give more variability on the seating position. Also increased the height of the tank to raise ensure it is the highest part of the bike, a traditional stylistic factors of a cafe racer. not sure about the seat but think the farings and the covers under the…
XJ600e: Nobbly vs Race tyres
– Nobblies look much more interesting. – Nobbiles. More authentic, The great escape springs to mind. – Nobblies are my choice, more in proportion to the frame. Although some question the function of a nobbly tyres on a low bike with race posture and stance: – The seating position is head down, bum up, which…
XJ600e: BRAT / Cafe design?
Had a wee crack at simple brat style stance and panels with the 17inch wheels. The way it was set-up in the last photo it was too high. this still needs a fair amount of refinement and to visualisation from other angles but looks like it could be an interesting direction. Battery cooling is a…
XJ600e: 17″ rims
Put together a scale composition with 17 inch wheels. doesn’t look too bad. gives a good start for sketching. I have up to now bee hesitant to start drawing without an accurate start. Not good enough for modelling. Will have to get the frame scanned to make something good enough to make fairing patterns for…
XJ600e: Yamaha XJ600
Finally plucked up the courage to start building the electric ride. I found a 1991 XJ600 Yamaha steel frame to kick off the proceedings. Need to sort out the swingarm apparently the parts can be hard to find. The search begins.
XJ600e: QS Motor
http://www.cnqsmotor.com/en/article_read/QSMOTOR%2017X4.5inch%2012000W-14kW%20273%2096V%20120V%20Water%20Cooled%20DC%20Electric%20Hub%20Motor%20For%20motorcycle/538.html QS TEXT: Now, the new 17″X4.5″ mould is ready, it could be 12kW 273 70H, and 14kW 273 80H. The mould is made for water cooled version. It could also be customized to be air cooled. Please note the wheel, two side covers, stator are all new mould, not made by hand. So this…
An electrifying life on two wheels... 