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K.I.S.S. & the creative process, form follows function.

Today's kitchen
Chuey recently asked about the creative process. What part does it play ? Here's my example ...

I had sketched a design for a pair of brackets that would hold foot-pegs and controls:


But there was a problem
There are two lugs welded to each side of the frame behind the swing-arm pivot
intended to secure those brackets.
The clearance between the two upper lugs and the swing-arm is insufficient for a fastener.
My thought solution was to tap threads into the lugs
such that nuts would not be needed to secure the brackets.

Another problem
The I.D. of the lugs will allow an M8 fastener to slip through,
but is a bit too large to tap M10 threads securely.
... M12 would leave too little 'meat' remaining on the lugs.

The creative process, a.k.a. the solution
A "Time-Sert" is usually used to repair lost threads
but should work perfectly in my situation of an irregularly sized bore.
The process of installing a Time-Sert involves boring the I.D.,
counterboring a slightly larger diameter to fix the 'lip' of the Time-Sert,
tapping threads to secure the Sert, and threading the Sert into place.

The K.I.S.S. principle and the creative process
Well, hell's bells, the foot pegs and controls pivot on a shaft that ends in a 10 mm-1.5 thread !
Why not eliminate the bracket all together and bolt the assembly directly to the frame:

Light-weight alloy plates will next be fabricated to fit between the frame and the foot-controls,
fixed at both the upper and lower lugs.
Essentially one plate will function as a muffler bracket on the shift-side,
and the other as a fixture for the rear brake cable on the brake-side.
To secure these plates, the upper lugs will also be 'Serted' to accommodate 10 mm -1.5 screws.

The pegs are tested jump up & down solid, as sturdy as the factory bits, and ergonomically correct.

Next on the list was a linkage for the shifter.
Solid stainless rod was on hand in the garage from a past project, and so it was cut, bent,
the diameter of the ends reduced appropriately, and then tapped with M6-1.0 threads ...
stock issue BMW clevises were used.
A simple affair and not very creative, I'm afraid. The K.I.S.S. principle rules after all:

Now that's a post! That's going to be one nice ride! I'd like to see as much of your process as possible.

Zombie Master wrote:Now that's a post! That's going to be one nice ride! I'd like to see as much of your process as possible. :P

Thanks, ZM !

In a consumer culture that simply wants to fork over the cash for the latest / greatest / fastest ...
without personal greasy and hands-on involvement –



I enjoy the process of designing and building !

A recipe for brake linkage in the works:

[quote="vanzen@rockerboxer.com"]K.I.S.S. & the creative process, form follows function.
it was cut, bent,
the diameter of the ends reduced appropriately, and then tapped with M6-1.0 threads ...
stock issue BMW clevises were used.
A simple affair and not very creative, I'm afraid. The K.I.S.S. principle rules after all:

Sorry man, but you don't get to say "not very creative" here. One thing is, that the factory made some pretty cool stuff and what I see is what the factory did as a launch platform. You are changing what you need to in order to make the bike meet your desires. It is almost as if you were working along side the talented folks who designed the bike in the first place. I'm sure they would like what you are doing. It is very creative to adapt.

Chuey

I like the timing chain cover.

Will there be a cover over the alternator?

Garnet wrote:I like the timing chain cover.

The product of a cutting wheel, files, BBQ paint, and an abundance of time.
A regulator / rectifier replaces the diode board and is located under the gas tank.
The Coil and it's bracket will fit to the engine case in that empty space to the left of the starter.

Garnet wrote:Will there be a cover over the alternator?

Yes. FRP and minimal – just to keep the road-crap out of the electrics.

Cut and threaded:

Nice stuff there Vanzen, bet you can't wait to feel yer ass pressing on the back of the seat.
Commitment is an appropriate word here.
Most personal projects of such a scale have the 'creator' at some point asking themselves 'what the hell am I doing' usually about midway through the project.
It's the little victories along the way that keep driving them to the ultimate conclusion.
Onwards and upwards man!

ME 109 wrote:...'what the hell am I doing' ...

Thanks, ME109 – I had to laugh when I read the part quoted above ...
A question that nags my brain often enough that it ought to be hand-painted right onto the damn bike !