Machining a stock flywheel and gears

[BastrdHK]

It's done.

I weighed it before I started (postal scale) and it was about 4.5 pounds.

2 pounds now

I reduced the OD big time, cut the rear face down by .200, and cut a big chamfer on the back side/od to get just that last little bit.

I did not get a chance to work on the gears, but Im going to.

The box I used to carry parts in weight a *ton*  (Primary, flywheel and the gear behind it, cam drive gear) Discounting that it's rotating mass that I'm reducing, the static weight reduction should also be in the neighborhood of pounds.  How can this be bad?



I love cutting metal

My imagination is pretty good and all, but I am craving visual evidence......always makes a project more interesting

[2001cromo]

Maybe this will give you some more ideas




As another asked previously, are you interested in doing others/more?

[hypurone]

Wheels are also a big candidate for inertia reduction because they have a big R and are a substantial fraction of bike weight, you get two bangs for your buck, reduced rotating inertia and reduced straight path inertia.

2c

Oh yes, I loves me the light (CF) wheels!!   

I can only imagine how much bigger the effect (and it was huge  ) would have been had I not started with the fairly light Marchesini's that came on the bike. Makes me think about those "HEAVY" wheels on all my jap bikes....and the diff that would have been made had I done the switch!

[BastrdHK]

Maybe this will give you some more ideas



As another asked previously, are you interested in doing others/more?

cromo,  where did you get the pic and who did the work?

[Capo]

cromo,  where did you get the pic and who did the work?

http://www.speedzilla.com/forums/ducati-classifieds/46923-lightened-gears.html

[TAftonomos]

That is Garrick Opie's work (or at least his picture).  Guy is a machining genius.  Made a fender for a 999 bike out of a solid chunk of billet.  #1 of 1, for MJ (Jordan) himself.  HAD to have been a 6 figure bike, probably at least 2 times over.

Those gears, as discussed, are hella hard to cut.  I believe the cost was ~$750 to do all the machine work, but it was a while ago I looked into that, so I could be wrong.

If the time ever comes to split the cases on my monster, you can rest assured everything will be shaved down (including the shift drum, and other internal bits).

Google Garrick Opie for some kick ass pictures of the 999 build.

[Monsterlover]

Maybe this will give you some more ideas




As another asked previously, are you interested in doing others/more?

Yeah, I guess I should post a picture of it, huh?

That picture. . .  perfect.  I think I just messed myself

I am interested in doing more, but I don't think I have enough access to a mill to do more than the few gears I have for myself.

That may change soon though, so stay tuned. . .

[Monsterlover]

Ok, got them done today.

As mentioned before, most machine shops wouldn't touch this project.

But I would    I did lots of touching.

I even have some pics for your viewing enjoyment.

[ENJOY]










[/ENJOY]

[Smokescreen]

There is a downside to negating the flywheel of course; compression braking...  Without flywheel inertia the engine compression will massively increase rear wheel lock on engine decellaration.  And of course, the fix for this is a slipper clutch, which weighs more than a stock clutch.  Sooo.......  Would you really want to nix the flywheel and replace that weight with a slipper clutch?

BTW, this is.... truely.....  motoporn!
W

[TAftonomos]

Any before/after weights?

The lightweight flywheel is easily purchased, more interested in the basket and primary gear....

[Capo]

There is a downside to negating the flywheel of course; compression braking...  Without flywheel inertia the engine compression will massively increase rear wheel lock on engine decellaration.  And of course, the fix for this is a slipper clutch, which weighs more than a stock clutch.  Sooo.......  Would you really want to nix the flywheel and replace that weight with a slipper clutch?

BTW, this is.... truely.....  motoporn!
W

My slipper clutch is lighter than the stock unit.

The clutch rotates at less than engine speed so more effect is gained from a lighter flywheel.

Monsterlover, what type of cutter did you use HSS or cobalt? Did you break any?

[2001cromo]

Any before/after weights?

The lightweight flywheel is easily purchased, more interested in the basket and primary gear....

A stock steel clutch hub basket is 4 pounds.
A machined (like the old SBK's) steel clutch hub basket is 2 pounds
A stock aluminum clutch hub basket is 1 pound

No clue about the gears, would like to know about these too?

edited, to make the proper name of basket instead of the wrong name "hub".

[aaronb]

There is a downside to negating the flywheel of course; compression braking...  Without flywheel inertia the engine compression will massively increase rear wheel lock on engine decellaration.  And of course, the fix for this is a slipper clutch, which weighs more than a stock clutch.  Sooo.......  Would you really want to nix the flywheel and replace that weight with a slipper clutch?

BTW, this is.... truely.....  motoporn!
W

while engine braking will be (slightly) stronger once the clutch is engaged, a lighter flywheel will actually reduce wheel-hop if you botch a down shift.  Lighter internal engine components allow it to rev more quickly, so if you release the clutch 1500 rpm's off, it will take less work from the rear wheel to right the situation.  also i have found that the lighter flywheel makes it easier to match revs since it does rev more quickly now.   

i had mine machined last winter and would never go back, in fact i was thinking about going all the way and getting a lighter aluminum flywheel.   

[Monsterlover]

My slipper clutch is lighter than the stock unit.

The clutch rotates at less than engine speed so more effect is gained from a lighter flywheel.

Monsterlover, what type of cutter did you use HSS or cobalt? Did you break any?

Read a little further up in the thread.  I made some comments about HSS or HSSCO not being hard enough to cut through the "skin" on the gears.

Carbide all the way baby!!  I didn't break any cutters. . .

In fact, I could probably use them to do a second set.

I do this for a living you know

[TAftonomos]

A stock steel clutch hub is 4 pounds.
A machined (like the old SBK's) steel clutch hub is 2 pounds
A stock aluminum clutch hub is 1 pound

No clue about the gears, would like to know about these too?

Where would one find a stock aluminum clutch hub?   I know veetwo sells a billet one for 3-400.

Did ML lighten the clutch hub?

Could you be meaning the clutch basket?