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Custom wheel hubs and rotors http://www.pilotodyssey.com/PO/viewtopic.php?f=5&t=16507 |
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Author: | Pilot bird [ Sun Feb 28, 2016 10:45 am ] |
Post subject: | Re: Custom wheel hubs and rotors |
Wow! Nice work:() Are you thinking about making hubs and rotors for the pilot or odyssey? |
Author: | DMoneyAllstar [ Sun Feb 28, 2016 12:23 pm ] |
Post subject: | Re: Custom wheel hubs and rotors |
Nice work..cad, FEA and machining. Is this a class project or something? |
Author: | jcc [ Sun Feb 28, 2016 5:07 pm ] |
Post subject: | Re: Custom wheel hubs and rotors |
Pilot bird wrote: Wow! Nice work:() Are you thinking about making hubs and rotors for the pilot or odyssey? Seeing how these hubs have a similar bolt pattern to what's used on the pilot, I'm considering making a set of front hubs for the pilot. I'd like to see an option for a disk brake setup that didn't require cutting the stock spindles or changing rims or knuckles. I'm not sure how custom rotors could be beneficial for the pilot or odyssey, unless parts are getting hard to get. |
Author: | DMoneyAllstar [ Wed Mar 09, 2016 12:41 pm ] |
Post subject: | Re: Custom wheel hubs and rotors |
Any idea on how much the EDM costs? Would be nice to see what it'd cost to build a set of axle adapters for the stock FL350 box. Would have internal Honda-25-spline, 2 holes for the axle retention, and then perhaps a type-2 VW axle (or some other popular/cheap CV). Its basically what Methodical and I have been playing with recently. Also wonder what EDM costs vs. what jknarfal had done with the shaper (?) on his alternative output shaft. Would be slick to have an adapter like this... Attachment: fghfghfghfghfghfgh.jpg [ 28.66 KiB | Viewed 5131 times ] Or even one like this where you'd use the stock Honda Oddy/ATC rear wheel hub (with retention bolt holes added) and then use an adapter plate like this... Attachment: 1644.jpg [ 55.47 KiB | Viewed 5131 times ] |
Author: | jcc [ Fri Mar 11, 2016 4:01 am ] |
Post subject: | Re: Custom wheel hubs and rotors |
DMoneyAllstar wrote: Any idea on how much the EDM costs? Would be nice to see what it'd cost to build a set of axle adapters for the stock FL350 box. Would have internal Honda-25-spline, 2 holes for the axle retention, and then perhaps a type-2 VW axle (or some other popular/cheap CV). Its basically what Methodical and I have been playing with recently. Also wonder what EDM costs vs. what jknarfal had done with the shaper (?) on his alternative output shaft. Would be slick to have an adapter like this... Attachment: fghfghfghfghfghfgh.jpg Or even one like this where you'd use the stock Honda Oddy/ATC rear wheel hub (with retention bolt holes added) and then use an adapter plate like this... Attachment: 1644.jpg From what I've been researching, EDM cost depends a lot on setup and machine time. EDM in generally is very slow and speed is measured in square inches per hour (accounting for depth of cut). Some people quote by the amount of area needed to be cut, so that's the total distance traveled by the wire times the depth of the cut. So cutting the external profile of large gears is going to cost much more compared to tiny gears. If you can provide the shop with the spline specs, or the mating shaft and center distance, they can be up and running the machine in short order. Other than for tiny gears, a shaper will probably overtake the wire machine by the 2nd or 3rd part. Unfortunately, Honda seems to use non standard splines, such as a 37.5 pressure angle on the CV shafts below. From machinist forums, I found that depending on the machine, you're looking at about 0.075" per minute (newer machines may go 3-4 times as fast). So you can probably get a rough idea of cost incurred due to machine time based on the speed, the total area to cut for both roughing and finish passes, and $80.00 per hour. Factor in setup and programming time on top of that. In addition to those four inserts, three spool gears were sent to have internal splines cut to meet up against a Can-Am shaft (the axles use a custom length shaft in addition to the inboard Can-Am and outboard Foreman 450 CV's). So for a total of 7 items with 2 different setups (both CV's have the same spline data), the value was a few hundred dollars. That first adapter would be relatively easy to do (assuming you were only doing the splines), and for a set of 2, I'd imagine you would come in around a fraction of that cost. If you were mass producing them, I'd imagine investing in a custom broach would be nice. I'm not quite sure how the second adapter would be used. Could you explain a little more? |
Author: | jcc [ Sat Mar 12, 2016 3:45 am ] |
Post subject: | Re: Custom wheel hubs and rotors |
Pressed some bearings, seals, and studs into one of the front hubs today. This hub is ready to be mounted. |
Author: | DMoneyAllstar [ Wed Apr 06, 2016 9:18 am ] |
Post subject: | Re: Custom wheel hubs and rotors |
Very nice! |
Author: | canadian oddy [ Fri Aug 12, 2016 1:22 am ] |
Post subject: | Re: Custom wheel hubs and rotors |
So what became of this project ?? |
Author: | methodical [ Fri Aug 12, 2016 6:47 am ] |
Post subject: | Re: Custom wheel hubs and rotors |
DMoneyAllstar wrote: Any idea on how much the EDM costs? Would be nice to see what it'd cost to build a set of axle adapters for the stock FL350 box. Would have internal Honda-25-spline, 2 holes for the axle retention, and then perhaps a type-2 VW axle (or some other popular/cheap CV). Its basically what Methodical and I have been playing with recently. Also wonder what EDM costs vs. what jknarfal had done with the shaper (?) on his alternative output shaft. Would be slick to have an adapter like this... Attachment: fghfghfghfghfghfgh.jpg Or even one like this where you'd use the stock Honda Oddy/ATC rear wheel hub (with retention bolt holes added) and then use an adapter plate like this... Attachment: 1644.jpg I love this! Man I need to convert my mill to CNC... Anyway, I'm still working on the FL350 output shaft adapters. The plan is exactly as Dmoney said, internal Honda splines, 2 cross bolts for retention and the ability to be used with different CV's. I don't recall seeing what you paid for the EDM process, what approximately did it end up costing. I'm weighing my options. I may move forward with having a couple custom pull broaches made, seems to be the most efficient choice for spline many sets.. From discussing the splining process with jknarfal, doing it manually is way to resource intensive.. I must say though, I thoroughly enjoy reading these SAE projects. The creativity and scientific/engineering thoughts that go into theses builds is spectacular.. |
Author: | jcc [ Sun Oct 02, 2016 1:14 am ] |
Post subject: | Re: Custom wheel hubs and rotors |
We traveled out to Lebec, California for the competition. The competition mainly focused on a 4 four endurance race, but there were some some side events, such as a hill climb, maneuverability, and acceleration. My hubs and rotors performed pretty well. We were 25th out of 100 teams through the majority of the race, but a damaged brake line (rock) and consequential rollover gave us a delay. We finished 36th. Overall it was a lot of fun. Here are some photos: Overview of the track: Look at all the flags: Lining up for tech inspection: Gridding for the race: All the Big 10 teams (Left to Right: Iowa, Michigan, Michigan State, Nebraska, Purdue (us), Wisconsin. Illinois did not make the picture): Here's a video of the maneuverability course I created: Link in case above doesn't work: https://youtu.be/z-zOwrTPlO0 |
Author: | canadian oddy [ Mon Oct 03, 2016 4:13 pm ] |
Post subject: | Re: Custom wheel hubs and rotors |
That's cool. Congrats on even finishing, it's about engineering, honest competition and friendships. If engineering was the only factor I would give you the win hands down based on the pics I have seen here. I noticed flags from other countries in one of the pictures. How many if any foreign teams ?? Any idea how they made out ?? |
Author: | jcc [ Mon Oct 03, 2016 7:02 pm ] |
Post subject: | Re: Custom wheel hubs and rotors |
canadian oddy wrote: That's cool. Congrats on even finishing, it's about engineering, honest competition and friendships. If engineering was the only factor I would give you the win hands down based on the pics I have seen here. I noticed flags from other countries in one of the pictures. How many if any foreign teams ?? Any idea how they made out ?? Thanks! There were several foreign teams there. I remember seeing teams from Canada, Mexico, India, China, South Korea, Puerto Rico, and United Arab Emirates. Several teams from Mexico and Canada were able to simply drive to the event, but teams like South Korea and India actually had to ship their vehicle in a crate overseas. If you are curious about results for all the teams, they can be found here: http://students.sae.org/cds/bajasae/results/ |
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