Reproduction side covers

[jmcvey1]

Hey all,

I had an idea for a summer project (outside of finishing my bike) and wanted to get the communities opinion on it.

Through my university I have access to a CNC machine and all sorts of mold making capabilities which got me thinking, I could easily make molds of some side covers, then pour plastic and have some very accurate reproductions.

I know finding originals is hard and gets expensive, would anyone be interested in these if I got around to making them?

Thanks,
Joshua Cade

[James England]

I think you'll find that this has been discussed before although I seem to remember that it wasn't an easy process like the one you've outlined. What sort of plastic would you be using? Also, how would you include the fastening lug which attaches each panel to the bike? One of them locks on too..... Sounds interesting.

[TopCatGr58]

Hey Josh,

You're in a central location with plenty of XSives around, so I would think you should be able to get ahold of the variety of side panels from the different years to use as mold/modelling guides. Do you have laser measuring capabilities for being able to duplicate the curves and such?!

As stated, the left side cover has a locking tab which is commonly broken off due to new owners not knowing that it's locked, and the key is required to unlock it in the front, but there's often a dirt/water cover plate so they often don't see the lock key slot!

I've got a set off an 81 Standard that I can ship/loan to you if you need.
Good Luck.
T.C.

[Aaron]

Im interested. I need a lefty for my 80 special. I can find some fairly easily, but they are always in beat-up used condition and they still price em like they are a shiny new product. Im not gonna shell out that kinda money for 30 year old brittle plastic crap. But i would happily pay you that kinda money for a high quality new repro piece. Bring on the goods and commerce shall commence.

[WSL91]

Hey all,

I had an idea for a summer project (outside of finishing my bike) and wanted to get the communities opinion on it.

Through my university I have access to a CNC machine and all sorts of mold making capabilities which got me thinking, I could easily make molds of some side covers, then pour plastic and have some very accurate reproductions.

I know finding originals is hard and gets expensive, would anyone be interested in these if I got around to making them?

Thanks,
Joshua Cade

Are the side covers injection molded? I doubt that they are vacuum formed. Not sure what plastic you pour to mold. Do you have access to that type of equipment? I know on Honda's a lot of these type parts are ABS as is the Vetter Windjammer

[xswilly]

do you have the know how and software
to measure and create a 3d program for the cnc machine

as it is complex, and time consuming
it is not unusal for the machine to run 10 to 20 hours
to mill out a mold

[Yahman]

Not trying to high jack the thread, but I am in the final stage of product development and within the next few weeks, I will be offering a fix for the side covers with the broken tab. The repair kit will consist of black powder coated machined aluminum parts, and stainless steel hardware. When fixed, the side cover will attach in the same way as the other side. The price will be $35.99 shipped.

Larry

[clcorbin]

The side covers are injection molded thermoplastic. Making the molds is NOT a trivial task simply because the final shape of the mold does not actually match the desired final shape of the part! This is due to the thermal contraction as the part is cooling and for an accurate mold, it must be taken into account. Unfortunately, it is also one of those areas that still fall a good ways into the "art" side of the house and is not 100% in the "engineering" side (YET!). Which means you need someone that actually knows how to design a mold to produced the proper part. And those guys are NOT cheap.

Also, do you have access to an injection molding machine that has the capacity (both in plastic volume and mold size requirements) to mold these things? Not trying burst your bubble, but when I saw the word "easily" in your original post, I knew you didn't fully understand what you are in for.

Good luck and I hope it works out!

[Rasputin]

What comes easily to one is not the same for another. If you make em people will buy em. Count me in if you can get it done.

[WMarshy]

The side covers are injection molded thermoplastic. Making the molds is NOT a trivial task simply because the final shape of the mold does not actually match the desired final shape of the part! This is due to the thermal contraction as the part is cooling and for an accurate mold, it must be taken into account. Unfortunately, it is also one of those areas that still fall a good ways into the "art" side of the house and is not 100% in the "engineering" side (YET!). Which means you need someone that actually knows how to design a mold to produced the proper part. And those guys are NOT cheap.

I have to disagree with your statement, and a few others here. There is plenty of literature out there to accurately account for shrinkage (giggidy). Plastic molding technology is not what it use to be, its not as much as an art form as it use to be. Anyone studying plastic engineering (or even a good mechanical engineering program) will have the tools/information available to properly adjust for shrinkage... Combined with new CAD/CAM technology, drafting the mold becomes fairly easy. Machining will be timely but colleges usually have a capstone project that combines 3D modeling/drafting with CNC machining... I know my college had a plastic engineering major before I attended so they incorporated a lot of plastics into my mechanical degree... Just my 2 cents.

[clcorbin]

I have to disagree with your statement, and a few others here.

You can't have a good argument unless you start with a good disagreement!!!

There is plenty of literature out there to accurately account for shrinkage (giggidy). Plastic molding technology is not what it use to be, its not as much as an art form as it use to be. Anyone studying plastic engineering (or even a good mechanical engineering program) will have the tools/information available to properly adjust for shrinkage...

There is a HUGE difference between having the information and being able to correctly apply it. Even the assorted CAD/CAM packages have huge limitations and unless you UNDERSTAND those limitations and how to avoid them or work around them (or just to know when it it is feeding you a line of crap), you will be walking with dragons. And I am graduating with my BSME in 4 weeks and have been using several of these packages extensively for the past few years...

Combined with new CAD/CAM technology, drafting the mold becomes fairly easy.

Much easier than it used to be, but still not easy. But, as I said in my original post, there was that (YET!) in there...

[jmcvey1]

Pour in plastics are pretty easy to use if you have the mold. I've done this once or twice.

As for the mold, I know Rhino very well and have (free) access to a CNC machine, machining the mold will only take a few hours, plus more time for sanding and all that stuff. It seems pretty doable.

THAT BEING SAID

it sounds like Yahman has this all worked out already and at 35 a pop, I may just buy a couple and skip the hassle.

[clcorbin]

it sounds like Yahman has this all worked out already and at 35 a pop, I may just buy a couple and skip the hassle.

Keep in mind one other thing: The personal satisfaction of knowing YOU made your own side covers!

[Joab]

Yahman is only making repair kits though, not the full side covers right?

[WMarshy]

You can't have a good argument unless you start with a good disagreement!!!



There is a HUGE difference between having the information and being able to correctly apply it. Even the assorted CAD/CAM packages have huge limitations and unless you UNDERSTAND those limitations and how to avoid them or work around them (or just to know when it it is feeding you a line of crap), you will be walking with dragons. And I am graduating with my BSME in 4 weeks and have been using several of these packages extensively for the past few years...



Much easier than it used to be, but still not easy. But, as I said in my original post, there was that (YET!) in there...

I graduated and obtained the same degree in 2010 and came from a large drafting and machining background prior to college so I already know the limitations and challenges of creating models and making molds. I have made a few in the past and although I don't claim to be an expert, I did have relatively easy success... Its not rocket science per-say but, I'm sure there is a lot I can even fathom. If I could make as well of a living doing drafting and machining I would have stayed in that field as it was a passion for me... If I had the time and access I would pursue more projects where I could apply that knowledge. Unfortunately it's not the case.