Suzuki RG250F Gamma conversion

[jonescg]

Yeah, and that's why solar panel installation mobs would be delighted to see their name ona high-profile E-vent like the TTX-GP.

So I spent the afternoon looking at the RG frame wondering about fairings. The original fairngs look so disgusting:


so I thought maybe I could come up with something new. That requires new moulds and lots of expensive hard work, so I thought again... what's a cheap alternative?

RGV250 gamma fairings! They look good and they might actually fit. Although the RGV was a V-tein, making it considerably narrower than the RG. Still, might be a good way to make things a bit more aerodynamic and look good.



I spent some time playing with MS Paint and I discovered it's a frocking useless program for this sort of thing


Still, throttle is on. Now I can sit there and make "WHRRRRRRRRRZZZZZZZZZZZZZZEEEEEEEEEEEE" noises

[Malcolm]

I spent some time playing with MS Paint ...

Know the feeling. I've been messing about with Sketchup, trying to make my bike look a bit 'sexier'. I'm quickly realising that my artistic ambitions far outstrip my abilities...

Sketchup is worth a look though. Take a look in Google 3D Warehouse (you don't need the software to do that). You can probably find a chassis that's similar to your bike and then borrow the fairings from another bike just to see how it looks.

[jonescg]

Picked up the twin Agni motor mounts today! A nice BIG +1 to Action Laser cutting - all this for $122. Sweet!



I just hope that Goodwill Engineering are as generous with their services

[AussieJester]

Picked up the twin Agni motor mounts today! A nice BIG +1 to Action Laser cutting - all this for $122. Sweet!

Thats justtoo good IMO, would take me days to make those by hand would readily
pay the $$$ for that ...best of luck with Goodwill Engineering tell em you
will throw a couple of their stickers on the bike when its done if they give you a decent discount

KiM

[jonescg]

Woohoo! Picked up a tank for the RG yesterday. It's steel, and weighs about 4 kg so I'd rather make a mould of it and get a fibre glass or carbon fibre one made up.


I'd actually like to keep the bottom clear so I can stack 4 sets of 3P, 8S batteries in the engine bay and up into the tank. It's going to need more aluminium fabrication. Something I wish I could do, but I'll have to wait.


Still, she looks more and more like a motorbike



And thanks to Cell_Man I have placed a deposit on some of his cells I just wish the Aussie dollar would get closer to parity with the US dollar though. I'm taking a trip up to Malaga and Wangarra tomorrow to get the motor mounts welded up. Crash bars should be done by then too.

[graemebc]

If you want a free PS type program get gimp. It handy for doing mock ups of project like this one on my mx5 track car.

[jonescg]

So I dropped my motors and mounts off to Goodwill for then to weld it all up. They even offered to pick up the bike so they can ensure everything fits perfectly I'm liking these guys already. I asked if they knew about sprockets for these sorts of applications, and he suggested motion industries in Malaga, Perth. They were literally up the road 1 km.

http://www.motionindustries.com.au/Default.aspx

Bugger me if they don't have exactly what I need They do 19 mm keyway hubs, perfect for Agni motors! And they even have a variety of sprockets in 428 pitch to suit! You could even weld two 19 mm hubs and a 15 tooth sprocket together and get a front sprocket for my bike all for under $60 !!!

Sprockets Oz can get stuffed! These guys are the bomb!

Crash bars haven't even been started yet Oh well, can't get it all right.

[jonescg]

So yesterday afternoon I came home and looked at the bike, thinking, what on earth will have the same weight and dimensions of an Agni motor, that I can hang of the right hand side to balance the weight of the left?

An Agni motor!!! Argh! I can't believe I didn't think of this before! It makes mounting it into the frame of the bike a lot easier too. So I called Goodwill and cancelled my work request, and ordered another plate be laser cut. This one is identical to the last one, and with the 10 mm hole in the meat of the plate I can connect it up to the existing mounts. It also leaves room in the centre for batteries.

Always improving...

Attached below are pics of the plans and some cardboard aided design

[jonescg]

Sprockets Oz FINALLY got my sprockets to me. 14T front with a 50 mm wide, 19 mm bore, 6 mm keyway hub to suit the twin-shaft nature of the Agni, and a 47 T rear to suit the rear sprocket of the RG. I would have prefered if they'd cut some lightening holes in the rear, but I might ask Action laser cutting to help me out

Oh, and the second plate is cut too, so I can take it all up to Goodwill and get it assembled!!

[AussieJester]

. I would have prefered if they'd cut some lightening holes in the rear, but I might ask Action laser cutting to help me out

Do i even need to say anything about my thoughts on this....

Nice looking sprockets though mate, good too see you are progressing steadily I always get excited when i get a notification email
of an update to your thread, i know there's more often than not some nice bling to lookz at

KiM

[pgt400]

Wow, 14/47.....thats pretty low. Good you'll have the torque of 2 agni's. Guess your looking for a high top end? What voltage?

[pgt400]

I've been looking for a 19mm bore, 12T, 420 chain sprocket for my Agni. I emailed them to see if they can source. I'm geared 12/72 with a top speed of 60mph on 72 volts. I plan to go to 84v soon which will bring it up to 70mph.

[jonescg]

Yeah, it is a bit tall, but I'm looking to get 180 km/h. My batteries will be running 105.6 V nominal, or 96 V for all intents and purposes. I am building this bike with 5 lap racing in mind, so longevity is not such an issue. I hope to get a variety of sizes depending on the curcuit I'm racing - more twists and turns = lower gears, lots of high speed stuff = taller gears.

Sprockets Oz will do anything you ask of them, but bear in mind it will take them a long time. I got them to take a triplex sprocket and remove the outer two rows of teeth. I think they also had to bore it out to 19 mm. 420 pitch is actually quite uncommon in the motorcycling world, so 428 is a good compromise. Motion Industries in Malaga, Perth are one of a large chain, and they might stock a few other bits and pieces. They definitely stock 19 mm keyway hubs and I think the smallest 428 pitch sprocket they can offer is 13T.

[maydaverave]

I used to have a hyosung gt250 comet which used the suzuki 500e frame which looks pretty similar to the frame your using. The fairings off the gt250comet r might work for you and you could probably find some for cheap. You can see both versions at this link.
http://www.cycledragon.com/hyosung-moto ... -250-r.php

[jonescg]

Cheers for the fairings link mate I worked out the RGV race glass from Tyga will fit with minimal dicking around. Still need to get the glass tank made up to make it look the goods.

So I got both motor mounts made up by Action (awesome shop that it is) and got to keep one of their duds. The holes didn't align properly so hey cut another for free.

I worked out if I drill another 10 mm hole just down a bit from the existing hole, I can fit them inside the frame a bit, and this leaves room to stack batteries right up close to the sprocket (not too close though ). The 10 mm rod with a tubulas sleeve works well to hold everything in place. I'm looking to get a high tensile bolt of 260 mm length to do the same - I don't think mild steel rod will cut it.

I also decided I can still use the 30x30 ally tube, but not across the frame, rather a hanging U shape to support the weight of low-slung batteries. And I can still use the 20 mm crash bars I'm getting made up. Gotta protect my investment





I also got my slab poured for all my hobbies. The Mrs wants the living room back

[jonescg]

It may look just like the last photo I posted, but you will notice the motor mount is now firmly attached to the original frame mounts with some nuts at either side.



I bought a die and threaded some mild steel rod, sleeved it with some steel tubing and put the dud plate as well as the good one on to see how she looks - and I think it's a winner! I haven't driled the new hole for the RHS mount as I will wait until I have both plates and I can accurately do them at the same time. I'll just get Goodwill to fill the original hole in (it was always going to be a bit of guess work).



In future I will try to get my hands on an M10 high tensile bolt about 265 mm long - should be a bit stronger than mild steel I would hope. But now all that remains is to get the plates welded together with 16 mm solid ally rod, and to mount the battery saddle in place:



This way I can use the crash bars I got made up, and still leave room for a battery at the lowest point on the bike.

Can't wait to get things moving... Might as well order another sprocket - should be here by June

[cell_man]

Hi Chris,

it's looking good Sorry I didn't pop by to say hi before, never ventured to this bit of ES before. Will make sure I get by more often in future.

Like I was saying before I've made a bit of progress on the terminals and should have something I can show you tomorrow. I need to get some more copper bus bar before I can do much more and everywhere is shut for the rest of the week here. I've cut and drilled 6 of the terminations, so only another 26 or so to do...., plus all the little threaded clamps that are required. Hopefully it doesn't take too long till you got something to fill that frame. Those Kokam bikes won't know what went past them

[spdas]

Hi, maybe I am not following well, as I don't see how the Agni's will bolt to the motor mounts with that bolt going through and the ears of the frame in the way, or is it just an illustration? thanks
francis

[jonescg]

The motors go to the outside of the frame, shafts point inwards. These two motor plates will be welded together with 189 mm lengths of aluminium tube, leaving room for the sprocket and chain, of course

[spdas]

Aloha, I guess I had a DUH moment. Weird, as I must of looked at your mount pix for 15 minutes late last night and didn't figure the motors to be on the outside. "Tunnel vision"

francis

[Jay64]

Ok, you guys were right, the sprockets I got from surplus center were 3/4. But they fit the agni just as well as the 7/8 fits on the Mars. I can't notice any slop. And for $5 a piece, I feel they are definately the way to go.

Just in case anyone else is interested the item numbers are:
1-2124-14-c for the 14 tooth
1-2124-13-c for the 13 tooth

[jonescg]

Hi Jay,

Yeah, I'd say the imperial sprockets would fit OK with not too much slop. If you really torque down on the grub screws it won't move much.

I am getting Sprockets Oz to make two more sprockets (12T and 13T) with 19 mm bores and 6 mm keyways, and I will get my mate Luke to turn up a hub which joins them. This way it will accommodate the off-set chain location and being double-ended I can swap it around according to the circuit I'm racing. I know they're slow, but they do a good job.

[jonescg]

Sprockets Oz have finally pulled their finger out and reply to my requests a bit quicker I got a 12T and a 13T made, and as they are off-set I should be able to put the heavy end where the chain runs, and the light end will have plenty of room for a shaft extension.

[only1jake]

Nice, They look like good quality sprockets. I was wondering.. When are you planning to have this build done by? And Don't forget to take some photos when you mount the sprockets and motors!!!!!!!!
Looks like its going to turn out nice Kelly controllers have finally dispatched my on Monday. Might even be here by the end of the week . The stuff is in Singapore at the moment lolz, I will take loads of photos when it arrives
Good luck with the project

[jonescg]

I want to have a working bike by the Perth Sun Fair, which is on the 28th of March. A very tight timeline, but it doesn't have to be perfect. At least it will look the goods on the day.

More specifically, if the specs are good, I want to race my bike in the UK TTX-GP. If not me, then some other Australian rider. I might well be the only (and first) Australian contender.

So maybe in about 2 months I will have a goer