Gearbox Modification.

[gidge348]

Hi Jon & Chris,

I have put my "Maintenance Manual" 420? Pages in my Dropbox account 230mb. I was lucky when I scanned mine, my brother had a print shop with a 120 sheet per minute scanner.... one cup of coffee and it was done

I have shared it with Jon (should have received an email), Chris if you want to send me your email I will share it with you as well ([e-mail]).

I have also put in another lot of training manuals and a folder of other misc stuff in the dropbox (aprox 80mb).

Ian...

[gidge348]

The shaft & gear are down at the machine shop still so have spent the time working on the governor mount to the quick change rear cover.

Firstly I had to take the gearbox governor shaft



The remove the gear and machine a slot in it and a matching one on the quick change rear shaft.



That way I could get drive to the governor and still be able to remove the cover.



Here are the parts, from the left governor, rear cover parts, manufactured bearing housing, bearing, spacer and clips, shaft & splines.



First assembled the spline



Then the bearings










Then bolted to the cover

[cursorkeys]

Hi Ian, thanks a lot for the email. It's been 16 hour days at work recently so I haven't had a chance to turn on my home PC yet but I will look ASAP.

Chris, that's a good idea. I don't know if I have enough upstream to make it sensible but I can certainly try. I'll see if I can get a dropbox set up tonight.


Edit: Nope, Dropbox limit is 2GB. So looks like memory sticks it is! Chris do you want to PM me your address?

[turbochris]

chris at krugtech dot com

I'm finishing my server up I'll either use that or up my dropbox account. I need this stuff for business anyway. Server would be done but one of 3 four tb hard drives was slopping around the box they came in. slide hammer style..... sounded like my little turbine when I spooled it up......

[gidge348]

Emails sent, let me know if you are able to get them?

Ian...

[gidge348]

Back to the saga episode 11...

Got the splined shaft and gear back yesterday and have been assembling the gearbox.

I still have 2 spacers to make up either side of the thrust bearing, but I want to put it together so I can get some measurements before machining.

The shaft has not heat treated yet but I will drop it down after Christmas. They recommend a 0.1mm nitro carburised case hardening as the actual shaft is almost at the hardness of the gear spline now after all the working.

As I said before the splines are 36 teeth rather than the 40 I originally thought of, they look nice and meaty.


I dug all the bearing out, cleaned them up and pressed them in.



There was no gasket between the faces so I used a black silicon to seal it.



Now it is starting to look like something.

[ozbooster]

Looks good Ian
Is the gearbox now within the diameter of the motor ?

[racket]

Hi Ian

Lookin' like a "bought one " :-)

Cheers
John

[gidge348]

Hi Greg, the gearbox is still longer than the total diameter of the engine, but my main reason for doing this was to get the drive in the right direction and shaft speed at a more useable level. Shorter gearbox is a bonus



It is 60mm deeper than the fuel filter, but that can obviously be moved.



It is 130mm deeper than the bottom of the accessory gearbox that realistically cant be moved.

When the engine is horizontal from the bottom of the gearbox to the top of the oil tank is 720mm.

Bearing in mind that I will be laying down in front of this, I don't think I could fit my ample frame (fat bast**d) plus helmet, Hans device, roll cage, body work etc into a height of less than 720mm.

The actual RADIUS of the gearbox (centre of input shaft to bottom of box) is 380mm.

Cheers
Ian...

[ozbooster]

Thats pretty good
Your not going to have the front wheel issues a motorcycle  will, our new liner is going to be 900 high , mainly so i can see the horizon above the 25" front wheel and 2" suspension and have the neccessary head clearance roll bar head plate and body and fit into the naca0009 shape from end to end , it adds up pretty quickly

[gidge348]

Hi Greg, if you have to be 900mm high to fit everything else, 720mm height should fit fine. I guess more of an issue will be the width?

The starter is a bit of a problem but if you have some type of scoop on the sides that will cover that.

I think this type of layout could still work for your bike, you could run down to a locked diff and run your chain off one axel and the hydraulic pump to drive the front wheel from the other axel.

Then have some type of adjustment in the lines to the front so you can make sure the front wheel turn faster than the rear, sort of rear wheel drive with front wheel assist. May he a bit easier to balance than hydraulic front & rear?

Cheers
Ian...

[ozbooster]

Ian the first liner will be twin turbo gsxr 750 motors , with hydraulic front wheel assist much like you describe , pump will be mounted on the output of an overdrive unit and chain drive from same point to rear wheel
any ratio changes happen between the motors output and overdrive
pretty well drawn up now and will get the plans to the chassis guy in the new year,
body from the plans will be fibreglass , a plug laser cut in styrene and make a mould then body from there
if the system works it will be easy to do again with whatever improvements seem needed for the turbine, basic shape would just about fit the Nimbus

[gidge348]

Greg,

I am really looking forward to seeing your project, who is doing the chassis work for you?

Are you going for 4130 or mild steel I am planning m/s for mine. I have been dealing with Woody in US for the aero work still a fair way to go with that.

Ian...

[ozbooster]

Wizard fabrication in Ipswitch gets to quote on the frame, He runs a turbo busa motor in a mini dragster and have communicated a bit during his build

be in MS , Jon B has done all the drawing,back and forwarding for 6 months on that, considered sending the info to Woody but also looking at a few online windtunnel programs and other stuff like openfoam, but think i'm reaching my limits and may just send it to Woody
But i know i'm on the right track when i found my shape is nearly identical to the Bubs liner, the real help probably would have been when i was deciding on flat bottom or rounded for yaw reduction,(went with round) the basic shape has lots of windtunnel and analysis info available online

I realy like what i saw when Woody was working with Jon on his liner , although it had a good shape to start with for going straight in no wind the inprovements made will allow it to run in mild cross winds, which your always going to get at least somewhere on the course

[gidge348]

I've been doing a bit of study on Solid works & did most of the drawings myself.

Have a few people here that can help with CNC machining, laser/plasma cutting, welding and fibreglass. I guess I will be doing most of the lump work myself and getting smart people in to do stuff beyond my capability.

I can generate Aero and FEA on solid works, the problem for me comes in interpreting it, that's the main thing I asked Woody to do.

I have been thinking about the floor as well, mainly the amount of ground clearance. After reading "the leading edge" I thought I want as much as practical to cut down shear drag. But Poteet & Main seem to pretty well with no ground clearance on the other hand Burklands & Vesco's are just as quick with ground clearance.

Seems to be more than one way to skin a cat....

Merry Christmas
Ian...