Falkonworks
Registered
Made a few revisions to the lower clamp design. The one I posted before was getting a little on the heavy side. V2 achieves my goal of 1 lb weight loss.
StreetShark's Hayabusa
- Thread starter Falkonworks
- Start date
Falkonworks
Registered
Got myself a new 3D printer for prototyping and for making some high quality and high strength end use parts. Testing some new industrial resins to hopefully come up with a few solutions as alternatives for expensive one off machined parts.
Falkonworks
Registered
I’m using a unique resin that I do not see talked about anywhere, but I chose it because of its strength and durability compared to all the regular resins you’ll find out there. I’m new to resin printing too, so this is all trial and error but I’ve spent the last 3 nights trying to dial in the print settings for this resin and I’m really close.
Here is a bar end plug for the carbon bars I would like to release soon. If you remember a few years ago I made a set of bars and added plugs that said Streetshark. I had purchased some generic plastic bar end plugs and laser engraved my old logo into them, made a mold and cast my own plugs. I no longer have that laser so I didn’t have a good way of making plugs. So that’s where the new printer comes in. This level of detail is incredible.
This new plug design is a from scratch design I made for my bars and added the embossed falcon logo to the face.
Here is a bar end plug for the carbon bars I would like to release soon. If you remember a few years ago I made a set of bars and added plugs that said Streetshark. I had purchased some generic plastic bar end plugs and laser engraved my old logo into them, made a mold and cast my own plugs. I no longer have that laser so I didn’t have a good way of making plugs. So that’s where the new printer comes in. This level of detail is incredible.
This new plug design is a from scratch design I made for my bars and added the embossed falcon logo to the face.
Hayabusa Wannabe
Registered
In another space-time where I actually did things right, I sit around and invent and prototype. I am very glad to see your work. It is fun and inspiring.
Yeah, I thought I had seen you there, you work just down the hall from me...
lmao
Hayabusa Wannabe
Registered
And we are smiling big, and greet each other daily, "Hey buddy", "Suuuuuuuup!", and nobody is riding our butts all day, and there is lots of free candy!
Falkonworks
Registered
Right or wrong is subjective. I just found an interest in one thing and it led me down a rabbit hole of acquiring tools just like any other hobby. If you genuinely have any interest in making things for yourself and can use something like a printer or cnc or whatever I highly recommend you try to make it happen.
I don’t have much free time outside of my regular career that pays the bills but I try to tinker when I can. In the case of the post from today, it meant 3 late nights up until around 1 am fooling around since the rest of my family was asleep. It’s very rewarding to see the things you have dreamt up actualized in real life.
Falkonworks
Registered
^And it’s never too late to try something new!
Falkonworks
Registered
First prototype printed aero disk carrier. I’m pretty happy with how this turned out. I made some lightening changes to this from the original design I have on the bike right now since it was a little over engineered. The changes I made don’t lend themselves that well to printing. I’ll need to add some thickness and/or ribs to give it some extra stiffness. This is a great start though.
Falkonworks
Registered
Made some design changes. I just decided to make the whole piece a solid dish, and I added ribs to the inside as well and I’m confident this will be rigid and durable enough now.
Unfortunately after all the testing I’ve done to get the setup working, and then my first prototype, I had a failure on this piece halfway through, and it left me with enough resin to only get through 70% of this print but it gets the point across.
Unfortunately after all the testing I’ve done to get the setup working, and then my first prototype, I had a failure on this piece halfway through, and it left me with enough resin to only get through 70% of this print but it gets the point across.
Falkonworks
Registered
working on the 2025 setup.
I picked up a carbon front end. I’ve had my eye on the ram air from this company for a while now but didn’t really want to spend the money on it. The whole front came up for sale used and I just decided to impulse buy it.
To be honest, the quality of the finish on pieces are not all that impressive but they are super light and from the photos I saw of the previous owners bike, they seem to fit decent. I’m only posting one of the side fairings, as I’m going to document the process of what I’m working on but likely won’t post much about it until it’s all done, but you’ll see the weave on the surface of the part has disturbances where it either was pulled when being layed, or it was already warped before it touched the mold. The other parts have similar blemishes as well.
Anyway, the original owner made some decisions when installing this kit and I’m making some efforts to correct those mistakes and make everything fit better and more correct.
First things I’m working on are the side fairings bolt locations, especially the left side. I’m doing some fitting for the quick release buttons I used on the OEM fairings and I’ll be adding some of my own material to the backside for extra support in these locations. This one the bolt hole was drilled off center and the head of the bolt was riding on the outside surface of the fairing (you’ll notice a chip in the resin in the upper right of the recess and obviously the bolt hole is wonky). Once I get the hole bored out to fit these buttons I’ll be adding material to support that area.
Like I said before, I most likely won’t be posting much about this project until it’s done as I’m working on a whole bunch of stuff behind the scenes to get everything finished up for Indy in May, and paint as well that I would just like to release as a finished product before showing the process. I’ll backtrack after it’s done and show the process though.
I picked up a carbon front end. I’ve had my eye on the ram air from this company for a while now but didn’t really want to spend the money on it. The whole front came up for sale used and I just decided to impulse buy it.
To be honest, the quality of the finish on pieces are not all that impressive but they are super light and from the photos I saw of the previous owners bike, they seem to fit decent. I’m only posting one of the side fairings, as I’m going to document the process of what I’m working on but likely won’t post much about it until it’s all done, but you’ll see the weave on the surface of the part has disturbances where it either was pulled when being layed, or it was already warped before it touched the mold. The other parts have similar blemishes as well.
Anyway, the original owner made some decisions when installing this kit and I’m making some efforts to correct those mistakes and make everything fit better and more correct.
First things I’m working on are the side fairings bolt locations, especially the left side. I’m doing some fitting for the quick release buttons I used on the OEM fairings and I’ll be adding some of my own material to the backside for extra support in these locations. This one the bolt hole was drilled off center and the head of the bolt was riding on the outside surface of the fairing (you’ll notice a chip in the resin in the upper right of the recess and obviously the bolt hole is wonky). Once I get the hole bored out to fit these buttons I’ll be adding material to support that area.
Like I said before, I most likely won’t be posting much about this project until it’s done as I’m working on a whole bunch of stuff behind the scenes to get everything finished up for Indy in May, and paint as well that I would just like to release as a finished product before showing the process. I’ll backtrack after it’s done and show the process though.
Similar threads
