The Bucket Foundry

**Flettner** · 28th March 2018, 18:02

Mmmm, hard anodized parts.

**Grumph** · 28th March 2018, 19:09

Saw you were hard anodising those gibs - or as I prefer to call them ASS - Aeroflight sliding segments...

Don't fully understand the rationale there. I know the Bighorn has lasted well past any life expectancy Kawasaki may have had but I wouldn't have thought you'd see a lot of wear on those bits for it's replacement.

**husaberg** · 28th March 2018, 20:08

Not foundry
I knew most Honda gears were made like this but i didn't know how much stuff is now done this way.
First video is short
second shows the whole process and how it works etc.

**WilDun** · 29th March 2018, 07:20

Originally Posted by husaberg

Not foundry
I knew most Honda gears were made like this but i didn't know how much stuff is now done this way.

Good find Husa - very interesting!
It's really just a good example of how foundry is morphing and (to me) this is most suitable for high volume production.
The first time I really took notice was when caride tips for machine tools started to become popular in the late sixties but it's certainly progressed since then.
However the first time I actually came into contact with the process was in an Ariel Arrow gearbox where they tried to be cheapskates by making one of the bearings in the gearbox out of sintered iron! - that wasn't a howling success I might add.
The idea was that the loose bond would made it porous, therefore keep it permanently lubricated with oil, however, normal bronze was (often) used as a replacement when the iron failed!

**Flettner** · 29th March 2018, 07:23

Originally Posted by Grumph

Saw you were hard anodising those gibs - or as I prefer to call them ASS - Aeroflight sliding segments...

Don't fully understand the rationale there. I know the Bighorn has lasted well past any life expectancy Kawasaki may have had but I wouldn't have thought you'd see a lot of wear on those bits for it's replacement.

the hard Anodising is not for the rotary valves benefit so much as its because these GIBs slide in an aluminium housing so will wear quickly. Hard against soft, you know
it.

**Grumph** · 29th March 2018, 08:45

Originally Posted by Flettner

the hard Anodising is not for the rotary valves benefit so much as its because these GIBs slide in an aluminium housing so will wear quickly. Hard against soft, you know
it.

Yeah, but I'm a cheap bastard, probably would have used brass.

Hard against soft, I think I can remember back that far...

Sintering - while I can't see what Husa has posted, it's definitely the way of the future for a lot of components. GM I believe were using it to make conrods a while back. Pretty well all valve guides in modern 4T's are now sintered. Every modern bike gearbox I've pulled down seems to use sintered shift forks now. Except for the Classic replica stuff which as they're small batch production are using investment castings.

**Flettner** · 30th March 2018, 11:09

GIBs installed
throttle belt lay out, bottom pully will be on an eccentric bearing housing for system tension, top pully will have the TPS and cable drive quadrant (throttle cable). left hand pully is 10T , right hand pully is 12T, I want one to open a little more than the other.

**F5 Dave** · 30th March 2018, 13:50

That is cool. I still dont fully understand it, but its still cool.

**husaberg** · 30th March 2018, 15:43

Thank god I don't either.
This I different from the original one Neil?

**TZ350** · 30th March 2018, 15:56

Originally Posted by Flettner

GIBs installed, throttle belt lay out, bottom pulley will be on an eccentric bearing housing for system tension, top pulley will have the TPS and cable drive quadrant (throttle cable). left hand pulley is 10T , right hand pulley is 12T, I want one to open a little more than the other.

Very Clever.

You need to go to the original post to see the pictures but this is a very interesting project. Throttling the inlet and changing the inlet timing by opening/closing the aperture on the rotary valve cover.