Cushman Head

I just finished machined aluminum Cushman cylinder head for Groff Machine.

Made from Mic6 cast tooling plate for it's dimensional stability and low inherent stresses, it also has a relocated spark plug position, 14mmx1.25 plug threads, increased cooling fin area and a revised combustion chamber shape to accommodate larger valves and cylinder bore. 

I used a long .125"dia. ball-end mill with a lot of patience to get the fins cut, run time on the fin side was at least 6hrs. Despite the blocky appearance, there is a whole lot of free-form machining but it turned out well, cant wait to see it at home on an engine now. Just for kicks, I made an RP 1:3rd scale model for posterity using and Objet Eden 260v.

More Projects Coming!

Slow and steady progress

I've been working on what seems like 10 concurrent projects the last few months, trying not to neglect any one project, consequently I've only gone so far with each but whatev.. It's progress!

As far as the Jackhammer Scooter goes, I finally bought the front fork tubing and had it bent, I gotta' say there is a HUGE difference in price between .062" wall welded SS tube and .083" wall Seamless tube, Yowza.
I bought replacements for wrecked parts like a tire, wheel, bearings, ect. so I'm hoping to have a rolling chassis again fairly soon

Made a few bits for Speed Shop Design, which pretty damn cool to do I must say, And totally gratifying knowing that someone else with real skills trusts me enough to make something.

I really like my day job too, I just can't talk about it or show cool pics of parts or I'll be fired, jailed or worse hehe.. But here is a Sketchup version of my work environment: Something I just recently started playing around with and like A LOT.

I've recently committed myself to designing a high-flow, super$$$ race fuel petcock for the Vespa P. Silly I know, But I NEED it. No more leaning-out at WOT. All other mitigating solutions are null and void now(I'm looking at you "float bowl spacer" and SIP fuel valve!)

And lastly, work continues on the supercharger as well as my plan to redo the P.

Super Scooter

So I finally got around to taking apart the so-called "Jackhammer", It's been on the back burner for way too long now. About April 08' I wrecked it and it's been non-functional since. I never really finished this scoot, I got it running for a rally and kept on riding it, after all, why take apart a decent runner? But every time I looked at the thing, I'd think about how much more I'd like to do to it. Well, now's the time.

 

 Fortunately, I started rehabbing some of the front-end parts well before the move to Seattle. So the rebuild will mainly consist of:

1. Making composite bodywork

2. Minor Frame repair and powder coating

3. Remaking the front fork tubes, rear hub, handlebars, ect..

4. Buying any needed parts

5. Reassembly

So, Here it is torn down to the frame, first time since April 05'

  

So, First order of business is to start mocking up the bodywork and seating, stay tuned!

_More pictures here_

Vespa Learnin'

It was about that time, time to do something about that nagging problem of slipping out of gear. Anyone owning an older Vespa knows what I'm talkin' about... The shift-cross syndrome! Many a vintage owner has had to endure the gradually increasing frequency of sloppy and erratic gear changes up until the point that the bike is darn near unrideable, then and only then, biting the bullet to change out that small but oh-so-important piece of metal.

And this is an image of the "depth of disassembly" usually required to rectify that nagging little problem.
Really though, it's not that big of a deal except for the fact that you are certain to find all manner of other little things that need fixing, little things that make you wonder how this scooter lasted as long as it did... Furthermore, my penchant for "over doing it" had me improving and tweaking every last little detail as it were, turning a weekend project into a 2 week ordeal.

So here's some of the things I've done:
custom grind output shaft spacers, lapped head and cylinder mating surfaces, port matched carb and case, replace all "tiny bits", cleaned EVERYTHING, lightened flywheel, new points and condenser, all new gaskets, replaced cables. Also replaced tank cap gasket, front shock bolt, tightened seat spring, installed step-thru channel rubber mat, custom made front suspension cover, blah, blah, blah.. I'm leaving so much out here.
And after all that, getting this bike in good running condition, standing back and feeling very smug about it all, I decided to take it off the stand and guess what? The front tire slips off the ramp and bonks the front fender! Ugh, nothing is ever PERFECT.

btw, thanks Scooterworks for having everything I needed in stock. You care for my needs.

Another (new) workspace

Lately I've been putting off the supercharger to attend to more immediate needs, namely my work space.
I spent a lot of time just getting rid of junk in the garage and basement to make room for my stuff.
Finally, I've arranged everything in the garage to be functional and efficient as well as repairing my lathe and building a scooter work stand.
The stand was a "weekend project" that ended up taking 40hrs and a couple hundred bucks, but it's so worth it not having to crawl around on the floor while working on the scooters. And as usual, I went way overkill on the construction, casters, height levelers, forged eye bolts, grip tape, aluminum machined parts, ect..
Now that the work space is in order, It's time to get back to making scooter parts, The best damn scooter parts I can make.

Really small superchargers

So I'm back from chilly, snowbound and slushy Indianapolis!
I went with high hopes and returned with:

Sore feet

A lighter wallet

Better camera skills

Awesome industry contacts

And a whole lot of hope for the future.

As per 2009, I took along a prototype of a new product idea, It's a supercharger for under 250cc 4 stroke scooters and small motorcycles, specifically the Madass125. But because of the nature of the design, it should be easy to adapt to other vehicles also.

To give you a sense of scale, the impeller is 2" in diameter and the inlet to the compressor housing is a diminutive 1.1"

If time allows, I'll have a fully functional prototype in a month.

Indy Dealer Expo 10'

It's that time of year again, time to hoof it around the Indy Dealer Expo and check out all the new and interesting products. As usual, I'll be helping Steve at The Scooter Scoop by manning the camera. This will be the third year I've gone and I'm just as excited to go this year as the first year. Last year I tried to throw together a last-minute prototype of a part I was thinking about producing but didn't get much interest but that's ok because it was a total learning experience. This year will be much the same, I'm going to try and take some time off from my busy schedule of making stuff for other people to throw together a prototype of an idea I've had in my head for a very long time.. and hopefully show it around and get some feedback from people in the industry.

BST Blackstone's Carbon fiber 12" wheel

Getting comfortable..

Recently I was going through some photos from about 2 years ago
and I came up with this,

It's a tachometer mount I made for a vintage Sun tach
meant to mount to the steering column of a Model-A.

The car(and tach mount) belong to Ryan Cochran
from the famed Jalopy Journal and the HAMB.

Making cool parts for guys who are REALLY passionate
about their equipment is one of the things I really miss about Texas.

Settled in Seattle

After a 2300 mile drive and two days of unpacking and

storing our stuff, We've finally settled in.

Now my main goal in to find a nice steady and

hopefully interesting job here.

Monday I'm going to take a little time to stop by and

see all the shops I'vebeen reading about lately.

Cycle-Car

Red Soul

Eco Motors

 Cosmopolitan Motors

Moeller Design

CNC work

Lately I've been really been putting the Haas VF-2 to work making and modifying all sorts of things.

JSF parts for work.......and......Scooter triple trees.

Designing and making parts for high-performance vehicles

is what I love doing.