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rotax 617 and long travel conversion
http://www.pilotodyssey.com/PO/viewtopic.php?f=5&t=14265
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Author:  DMoneyAllstar [ Tue Mar 08, 2016 4:21 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Very nice work!

Nice to see so much activity with these '85's with modern hardware.

Author:  jcc [ Fri Mar 11, 2016 4:13 am ]
Post subject:  Re: rotax 617 and long travel conversion

jknarfal wrote:
ive been wanting a set of fenders for this project. but unfortunatly the dark side has the market cornered on replacements. i was very hesitant to purchase these but i went ahead anyway. poor coustomer service and way overcharged for the shipping. but the fenders look great. i cant wait to get them mounted and hack big holes in them for the shocks. with a gloss black powdercoated frame to match and lots of shiny parts. i think itll look pirty damn good. these are just kinda proped up to get the idea.



Has anyone ever tried making their own out of fiberglass? You could cnc a mold out of renshape. Biggest challenge would be getting useful dimensions to start with, but I wonder if using a 3D scanner would be useful. Of course, you could always approximate the sizes of the bends.

A friend made a mold for a gas tank drip pan:
Image

You could probably also use plastic as well and simply heat the material up while vacuum forming to the mold.

Author:  jknarfal [ Fri Mar 11, 2016 11:04 am ]
Post subject:  Re: rotax 617 and long travel conversion

This is my failed attempt at just that.

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Author:  jknarfal [ Fri Mar 11, 2016 11:58 am ]
Post subject:  Re: rotax 617 and long travel conversion

Roman French has built some very nice fiberglass fenders for his pilot. The best I've seen yet. I started this and quickly realized I would have almost as much in material as it would cost just to buy them new. I also have a roll of carbon fiber I wanted to do the top layer in. But again I'm not a fiberglass worker. I know just enough to get me in trouble. That and I figured It would take a ton of labor. Now I can focus that time on the rest of the odyssey. I still have soo much more to do. And easily another $3k I need to put into it.

Author:  jknarfal [ Sun Apr 10, 2016 10:30 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Got some material the other day. Started on the bearing carriers. This is the same basic design as the pilot. Unfortunately the shaft I'm using isn't quite long enough to use the inner seal. I don't plan on running this through water or mud. Only sand. So well give it a try if it doesn't hold up ill build something else. Added some slots to the shoulder inside so the races can be driven out with a punch if necessary.

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Author:  jknarfal [ Sun Apr 10, 2016 10:41 pm ]
Post subject:  Re: rotax 617 and long travel conversion

I'm thinking I may be able to machine up a small ring that can be welded to the axle cup fo a bearing surface. I'll have to pick up some seals and see what I can come up with. Even if I were to get a seal big enough to ride on the outside of the cup. It be better than nothing. I still have to build spline adapters to run these hubs.

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Author:  mudbogger [ Mon Apr 11, 2016 9:52 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Keep it up, the ideas are getting and better, and the help you are giving to the 350 guys is going a long way, I have never in many years seen so much interest and kits out for the ody's, I love the fresh attitude toward open sharing of the tech, the ideas, everything about what your doing here.

Author:  jknarfal [ Tue Apr 12, 2016 10:58 am ]
Post subject:  Re: rotax 617 and long travel conversion

I love these machines. By sharing information hopefully it helps others. If nothing else it just inspires them to do stuff to there own odysseys. I ordered a seal that might work for me as a inner. I have a plan that should work. The more I thought about it the more I think I need that inner seal. Even if it means starting over on the carrier.

Author:  jknarfal [ Thu Apr 14, 2016 11:03 am ]
Post subject:  Re: rotax 617 and long travel conversion

I finally found a seal that should work for me. After lots of online searching and multiple trips to the parts house. at $17 ea! I'll make up a new carrier with the area for the new seal and make a ring to add to the cv for it to seal against.

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Author:  mudbogger [ Sun May 01, 2016 3:08 pm ]
Post subject:  Re: rotax 617 and long travel conversion

How goes the project? Interested in the rear carriers!

Author:  jknarfal [ Sun May 01, 2016 7:04 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Here's the revised carrier. I made it a 1/4" longer to accept this seal.

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Author:  mudbogger [ Sun May 01, 2016 7:20 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Nice work sir, is that a Pilot rear hub?

Author:  jknarfal [ Sun May 01, 2016 9:08 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Yes I still have to make up some spline adapters for it. I'll weld this ring on the axle so that the inner seal has something to ride on. The bearings and outer seal are pilot. I intend to weld a plate to this carrier with several holes in it for mounting to the trailing arm. I plan to do this in a manner that I can shim. To adjust the toe.

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Author:  jknarfal [ Thu May 26, 2016 10:29 am ]
Post subject:  Re: rotax 617 and long travel conversion

finally got some chrome! ill try to get this reassembled this weekend. i have already refinished the front plastic and it came out great. this will make for a great upgrade to this odyssey.

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Author:  jknarfal [ Sun May 29, 2016 12:37 am ]
Post subject:  Re: rotax 617 and long travel conversion

Picked up my controller today. It came out great. I'm very pleased with the plating. This really cleaned up nice. I sent out all the cage hardware along with the cylinder head nuts and some other random hardware to be done also. When I get the suspension built I will probably have the arms and links done too.

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Author:  fully [ Sun May 29, 2016 1:00 am ]
Post subject:  Re: rotax 617 and long travel conversion

Looks pretty good. Can a guy replace the grips with any mx grip?

Author:  jknarfal [ Sun May 29, 2016 1:20 am ]
Post subject:  Re: rotax 617 and long travel conversion

No the grips are unique to the 350s and pilots. They have a seam on the back side and can be removed by submerging them in boiling water. That will soften them up enough to work them off. The original controller I had installed heated hand grips too. You couldnt tell they were there. I'm not sure if ill add them to this one or not. I plan to run a trace line through the seat before I have it reuplostered. So ill have a heated seat. If it works out I won't need the heated grips.

Author:  solo0879 [ Wed Jul 06, 2016 3:13 pm ]
Post subject:  Re: rotax 617 and long travel conversion

As a machinist, I can say that you've done some excellent engineering and work to your build. I look forward to seeing it all come together. I'm sure it will be an incredible machine.

Author:  jknarfal [ Sun Jul 24, 2016 10:42 pm ]
Post subject:  Re: rotax 617 and long travel conversion

solo0879 wrote:
As a machinist, I can say that you've done some excellent engineering and work to your build. I look forward to seeing it all come together. I'm sure it will be an incredible machine.

Thank you I hope to get it done someday. It's taking forever! But I don't want to skimp on the detail. Got some more chrome done

Author:  jknarfal [ Sun Jul 24, 2016 10:46 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Cage bolts

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Author:  jknarfal [ Sun Jul 24, 2016 10:49 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Head nuts

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Author:  jknarfal [ Sun Jul 24, 2016 10:52 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Parking brake arm

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Author:  jknarfal [ Sun Jul 24, 2016 10:55 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Custom engraved Farr side plate

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Author:  jknarfal [ Sun Jul 24, 2016 11:21 pm ]
Post subject:  Re: rotax 617 and long travel conversion

Cage bolts. These will look great with a gloss black powder coated frame.

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Author:  solo0879 [ Mon Jul 25, 2016 1:27 am ]
Post subject:  Re: rotax 617 and long travel conversion

Ocd is a b*tch...lol. i had a part for airbus that had .003" tolerance, so .0015" was nominal. At those tolerances, you learn patience in your work. Take a little extra time, and do it right the first time, rather than scrapping it trying to rush it. Try percision boring with .0004" tolerance...lol.

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