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rotax 617 and long travel conversion
http://www.pilotodyssey.com/PO/viewtopic.php?f=5&t=14265		 Page 6 of 10
Author:  hoser [ Sat Feb 14, 2015 11:42 am ]
Post subject:  Re: rotax 617 and long travel conversion
jknarfal wrote:
Finally finished my brake caliper. I've been waiting on some seals. Found that a 2000 Chevy rear wheel cylinder boot fits great for a replacement parking brake boot.


Part number and source for the boot please.
Author:  jknarfal [ Sat Feb 14, 2015 3:47 pm ]
Post subject:  Re: rotax 617 and long travel conversion
Ok this is the boot I used. The counterman said it fit early 2000s chevy. I bought it at O'Reillys. A wheel cylinder rebuild kit is like 6 bucks. And contains two of these boots. These also have a plastic reinforcement ring on the larger side. This seems to snap into place and fits really nicely. It comes like in the first picture but the inner section inverts easily and seals tight onto the parking brake shaft. Anything I can come up with to replace these old obsolete parts I'm glad to try.

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Author:  jknarfal [ Sun Mar 22, 2015 9:55 pm ]
Post subject:  Re: rotax 617 and long travel conversion
It's been a minute since I've had time to work on this project. Ive been in need of the ability to cut splines. Both internal and external. After lots of research I decided to try this. They're not perfect but this was just a trial run. Have three different indexing plates so I have many options of index positions. It's a slow process on the lathe but it does work. I also picked up a old lewis shaper. So once I pick up a dividing head ill be trying it on that as well. Next try I think ill be building a new brake rotor hub. With internal splines.

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Author:  DMoneyAllstar [ Wed Apr 01, 2015 2:36 pm ]
Post subject:  Re: rotax 617 and long travel conversion
Very cool! Those shapers are beasts from the past, but they do the job well.

Any plans for hardening or heat treat?
Author:  jknarfal [ Thu Apr 02, 2015 1:18 am ]
Post subject:  Re: rotax 617 and long travel conversion
Yes i plan to ether attempt to harden myself or have it done. I'm still waiting on my output shaft at the machine shop
Author:  DMoneyAllstar [ Thu Apr 02, 2015 1:47 pm ]
Post subject:  Re: rotax 617 and long travel conversion
How about you make one out of carbon and EDM a female spline! :-)
Author:  jknarfal [ Thu Apr 02, 2015 3:24 pm ]
Post subject:  Re: rotax 617 and long travel conversion
That would be sweet but funds don't come easy. The first shop wanted over a grand to build the shaft. I may attempt it myself if its outrageously priced. I have several 350s so if this works out they all might get this mod.
Author:  jknarfal [ Sun Jun 21, 2015 12:47 am ]
Post subject:  Re: rotax 617 and long travel conversion
Well I finally gave up on finding a machine shop that could build my shaft for a reasonable price. So I decided to try a test run of the internal splines. This was my first attempt at this so i was unsure what would come out. It fits surprisingly well. I hope to get the proper material this week and get back on this project. I have been distracted by this new pilot and havnt put any time into this.

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Author:  jknarfal [ Mon Jul 06, 2015 11:45 pm ]
Post subject:  Re: rotax 617 and long travel conversion
Well I finally got a piece of chromoly to build this conversion shaft. It wasn't cheap. $50 a foot for 2" round bar. This doesn't look like much in this picture but I have most of the day invested into it so far. The left side has been bored and internal splines cut into it. I also had made a male splined shaft with a 1" shank to hold the material from the inside. And clamps up nicely in a 1" collet. Now it should be turning true to the axle and I have the entire outside profile free to cut without resetting and loosing zero. I'll post more as I go.

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Author:  jknarfal [ Tue Jul 07, 2015 11:31 pm ]
Post subject:  Re: rotax 617 and long travel conversion
Outside profile done. Now she's ready for splines and some threads. It's beginning to take shape.

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Author:  rmesser [ Wed Jul 08, 2015 1:19 pm ]
Post subject:  Re: rotax 617 and long travel conversion
Great work - keep it up.
Author:  jknarfal [ Wed Jul 08, 2015 11:36 pm ]
Post subject:  Re: rotax 617 and long travel conversion
A bit more done

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Author:  bullnerd [ Thu Jul 09, 2015 8:59 am ]
Post subject:  Re: rotax 617 and long travel conversion
Nice job J'.
Author:  jknarfal [ Thu Jul 09, 2015 11:01 am ]
Post subject:  Re: rotax 617 and long travel conversion
I currently have about 13hrs into this. The splining is incredibly time consuming. I have a diagram I drew up with the measurements. When I get done ill post it so others can attempt this if they desire. I'll do some more on it this evening.
Author:  canadian oddy [ Thu Jul 09, 2015 1:46 pm ]
Post subject:  Re: rotax 617 and long travel conversion
jknarfal wrote:
I currently have about 13hrs into this. The splining is incredibly time consuming. I have a diagram I drew up with the measurements. When I get done ill post it so others can attempt this if they desire. I'll do some more on it this evening.


Looks like you got some skill there -- nice job.
Posting the drawing would be cool.
Author:  jknarfal [ Thu Jul 09, 2015 3:24 pm ]
Post subject:  Re: rotax 617 and long travel conversion
I'm learning as I go. I bought the lathe a year ago and have been using it every chance I get. I've always wanted to get into machining but have never had a opportunity to get a good lathe at a reasonable price. I picked up this Logan 12" turret lathe and a rotex mill for $1500 with tons of tooling. I also have a larger enco mill and a Lewis shaper.
Author:  jknarfal [ Thu Jul 09, 2015 11:38 pm ]
Post subject:  Re: rotax 617 and long travel conversion
Brake rotor hub splines.

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Author:  canadian oddy [ Fri Jul 10, 2015 11:01 pm ]
Post subject:  Re: rotax 617 and long travel conversion
jknarfal wrote:
Brake rotor hub splines.


Just curious but what kind of cutter is that when you make the splines ??
Is it just a regular thread tip or is it a special angle ??
What is the angle on that tool ??
Author:  jknarfal [ Sat Jul 11, 2015 12:47 am ]
Post subject:  Re: rotax 617 and long travel conversion
It's just a regular piece of tool steel. I just ground it to the profile of the the slot using the original shaft as a guide. I'm sure there's a way to do it properly but I just did it by eye. Then I coated it with layout dye and test fitted. The high spots will appear. Made adjustments and continued until it fit good.
Author:  canadian oddy [ Sat Jul 11, 2015 7:22 am ]
Post subject:  Re: rotax 617 and long travel conversion
jknarfal wrote:
It's just a regular piece of tool steel. I just ground it to the profile of the the slot using the original shaft as a guide. I'm sure there's a way to do it properly but I just did it by eye. Then I coated it with layout dye and test fitted. The high spots will appear. Made adjustments and continued until it fit good.


Very nice job, I like it. Thx for the reply.
One more --- how did you make the inside splines ??
Author:  jknarfal [ Sat Jul 11, 2015 1:33 pm ]
Post subject:  Re: rotax 617 and long travel conversion
Here are some more pics. The internal splines are done in the same method. Just a different cutter. All that is left is the threads to retain the brake rotor hub. The new hub will have the larger splines and will use a new buell rotor. The retainer nut I'm using came off the engines crank shaft.

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Author:  jknarfal [ Sat Jul 11, 2015 3:19 pm ]
Post subject:  Re: rotax 617 and long travel conversion
Finally done! At least for now. I will send it out for heat treatment and when I get it back I will finish cutting the bearing surfaces with a tool post grinder. Then she'll be ready for installation.

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Author:  B S [ Sat Jul 11, 2015 5:06 pm ]
Post subject:  Re: rotax 617 and long travel conversion
jknarfal wrote:
Finally done! At least for now. I will send it out for heat treatment and when I get it back I will finish cutting the bearing surfaces with a tool post grinder. Then she'll be ready for installation.

damm nice work
Author:  jknarfal [ Sat Jul 11, 2015 5:27 pm ]
Post subject:  Re: rotax 617 and long travel conversion
Thanks I'm glad to get it done I've been waiting on this so that I can install the axles and finish the rear suspension.
Author:  DMoneyAllstar [ Mon Jul 13, 2015 8:23 am ]
Post subject:  Re: rotax 617 and long travel conversion
<Applause> Well done, sir! :-)

I'm jealin' on your machine inventory and your free-time!!
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