Carbon Fiber Project (03-22-11)

[Hornet Handler]

Just an FYI on the ARP studs. They are a great stud for holding things tight. However stock studs are 9mm and the ARP studs are 8.5 mm. So what happens over time is that the ARP studs put to much stress on the threads and eventually under the right conditions the threads let go. They just do not hold on to enough thread. If they were exactly the same size as the stockers they would be perfect.

Its nice to be able to torque down even more then stock (45 vs. 32) but add a little heat and vibration and the threads just pop out. Learned the hardway is all. Have a brand new cylinder with 100k on it and cant use it couse the arp studs pulled the threads out.

So this experience was on a Grizzly ATV, and not a Nytro? Repair the cylinder with quality thread inserts......not Helicoils......it'll be good to go.

 

[WolfOne]

Here it is some news about my project.

Family and job status don’t leave me lot of free time but I’m slowly going on with the project during night time.

After checked all measurements I ended to draw the chassis on autocad

Than it’s time to start the true job.
First I have to build a model. Than I’ll obtain a mold from the model.

The starting point seems to be close the ones of Nikolai and ricofmn … a sheet of plywood which leaves me a question ... I will be able to get a snowmobile from this?

No answer to the question till the end of the work so … go on drawing on the plywood

A check after the first cut … seems to align fine. Just some little mods and I try to install the bulkheads

Now the runningboards …also this step done and they fit well

Cloosing the top of the tunnel and placing the tank to check measurements
It starts to seem again a sled

There is a thing that I don’t love of my sled … the heavy nose … especially when I have to dig to be unstucked.
So I think that I’ve to transfer some weight from the front to the back … for example the tank
Let me try to take some mesurements

Yes it could work with a 31lt (8.2 gal) fuel capacity

I need space on the right side of the bulkhead for the new transmission and also want to clear-up the supercharger installation so … let I’ll try to replace oil tank an battery to the top end of the tunnel to have this weight centered on the sled … there is also a lot of room for electronics between the oil/battery and the thank

Need other plywood to build the bulkheads model and need also something to cure this cough and this cold

 

[rlcofmn]

I like the Idea of moving anything back thats possible, I moved my battery to basically the same spot as you along with getting my whole cooling system at the rear of the tunnel.

I like it! This is going to be a fun one to watch!!! keep up the good work

 

[WolfOne]

I like the Idea of moving anything back thats possible, I moved my battery to basically the same spot as you along with getting my whole cooling system at the rear of the tunnel.

I like it! This is going to be a fun one to watch!!! keep up the good work

Yes, all back!!
In the project the exhaust will be undertunnel with the muffler placed on the 45° area and there will be only a big radiator in rear upper area of the tunnel but it will "watch" both up and down tunnel taking snow from bottom and air from top.

... this is the theory ...

 

[Ruckus]

Yes this my engine after 30-40 seconds @wot on right side.

Ouch. Same here. Running uphill, trying to dig down to the kill switch, sled screaming away, oil running out of airbox....Damn, gives me nightmares.

 

[WolfOne]

Ouch. Same here. Running uphill, trying to dig down to the kill switch, sled screaming away, oil running out of airbox....Damn, gives me nightmares.

oh ... sincerly sorry for you ...

think that you also need an air-tether to be installed togheter with the rov-tether ...

 

[Nikolai]

Looks really good but doesn't the oil tank need to be as low as the bottom of the motor(or below the sump)?

 

[WolfOne]

Looks really good but doesn't the oil tank need to be as low as the bottom of the motor(or below the sump)?

I think it's the opposite ... the tank outlet need to be at level or higher than the engine oil inlet so that the oil could naturally "fall" to the engine going to fill the oil pan.
Otherwise the pump has to suck oil from a lower tank going to be overworked.

But i'll check to be sure because all the 4stroke engine I putted the hands on had internal tank (except the Honda XL 600 that had the tank in the upper chassis tube)
Better check twice and avoid another big damage.

Also I've to check the return line because the oil inlet in the model tank is 15" higher than stock and the pump has to push the oil a little more.

Nikolai, pls check my post on front susp geometry and tell me which is your opinion. Thx

 

[RTX]

looking at your build and it looks great. keep up the good work!
Just wondering. since you are doing a custom fabrication did you ever consider using the gastank and seat combination off a new skidoo to replace your tank and seat.
it is a pretty slick and light weight setup.

 

[WolfOne]

looking at your build and it looks great. keep up the good work!
Just wondering. since you are doing a custom fabrication did you ever consider using the gastank and seat combination off a new skidoo to replace your tank and seat.
it is a pretty slick and light weight setup.

Yes, i've think about this solution and also a combo of skinz seat with a custom made tank under it but all this solutions (and others) are 'bolted or riveted' to the tunnel.
I decided to incorporate the tank to the chassis so that tank will be also a 'structural' element reinforced from the inside.

I estimate that the weight of my one piece tunnel+engine frames+gas tank+oil tank+battery location could be 15kg / 33 lbs but the strength of the system should be at least double .
But this is to be confirmed after the wood model is ended deciding type and thickness of carbon fiber and after I figured out (and build) all flanges, threaded inserts, spacers etc

 

[philsummers21]

makes me want to just build a sled out of plywood and take her out on the snow. HA would love to see the looks on peoples face.

 

[WolfOne]

makes me want to just build a sled out of plywood and take her out on the snow. HA would love to see the looks on peoples face.

a good idea to reuse the model after i'll obtain the mold

 

[gormleyflyer2002]

great thread......you ever see "tour of lombardy" ? your home town ?

 

[WolfOne]

great thread......you ever see "tour of lombardy" ? your home town ?

If you refer to cycling race yes. It's one of the most common sport here in Italy but i don't like very much.

I'm from a small city close to Como (north of Italy close to Alps)

 

[swelly]

I am really watching this project. Carbon Fiber is so cool cause of weight and strength. Your day job must be a engineer or physicist.