So who is good at carbon fiber work?

[dbrutherford]

I really need to get this made and I am not as experienced in composites as I should be.

I want an X2 oil tank made out of carbon fiber. I am wanting it so that it will act as my e-box. I would like to have a lid that is sealed with a gasket or o-ring and bolted down. Then an aluminum plate would be epoxied inside where all the electrics for my 800 SXR engine would be housed inside. It would have the typical Kawie white threaded e-box connectors. It seems like a pretty simple and sano piece to make. I pulled all the electrics out of the 800 box tonight. The spark plug leads would be plenty long if the coil was mounted in the right place. The carbon oil tank would also make teh stock gas tank straps hold adaquetly. Only real concern is if my WB Limited chamber would touch it.

Any opinions?

 

[steveyz250fpilot]

Nice new parts. Too bad they will never get put on a ski. haha

Talk to Crammit

 

[madscientist]

let me see what i can do guys may or may not have something to show you at the chicken bone

 

[w-nut]

well if i lived closer i would do it for you but liveing on the other side off the world kinda rules me out . i work part time here http://www.dynamic-composites.co.nz/ . my cousin ownes it so he lets me play

 

[crammit442]

I really need to get this made and I am not as experienced in composites as I should be.

I want an X2 oil tank made out of carbon fiber. I am wanting it so that it will act as my e-box. I would like to have a lid that is sealed with a gasket or o-ring and bolted down. Then an aluminum plate would be epoxied inside where all the electrics for my 800 SXR engine would be housed inside. It would have the typical Kawie white threaded e-box connectors. It seems like a pretty simple and sano piece to make. I pulled all the electrics out of the 800 box tonight. The spark plug leads would be plenty long if the coil was mounted in the right place. The carbon oil tank would also make teh stock gas tank straps hold adaquetly. Only real concern is if my WB Limited chamber would touch it.

Any opinions?

It might be easier and just as cool to get an appropriately sized Pelican case.

 

[Scorn800]

How come you do not want to use the stock kawi box?
It already has a "O" ring seal and you know it fits everything.
I know D slicker used the stock box on his 800x2.

 

[dbrutherford]

How come you do not want to use the stock kawi box?
It already has a "O" ring seal and you know it fits everything.
I know D slicker used the stock box on his 800x2.

Where the coil rests inside the stock box, the wires are not long enough. He had his extended and told me that it just gave him problems and didn't like salt water. I was going to have the same company do them to mine so... I am looking at other options.

Basically this X2 will have custom everything so why not? It will just be a carbon fiber box with an aluminum plate inside that everything mounts to. I bought a carbon fiber old R Pot carbon fiber box but it is a hair too big. Plus I think a custom carbon fiber oil tank would save a pound or two over the stock 800 box.

Charles, do you have a link to the pelican cases? I googled it and found some military type stuff and laptop computer cases.

Hater Hypes right on cue! Could't resist could you? Where is your engine at?


DBR

 

[WFO Speedracer]

My engine is in the ski where it belongs,wheres yours?

 

[dbrutherford]

Sad to say but my engine is not installed yet... Had to poke at YZ some because his new engine isn't installed either.

So WeDo, you gonna make me a carbon box? I can attempt to make one yet I know my quality won't be what I want plus I will have a lot of $$ tied up in materials. I figured some of you composite folks already have the materials and could do it faster, easier, have better quality, and cheaper than if I did it myself. I am willing to pay accordingly for one. I even have a stock oil tank that can be used for ther mold making. I have seen Crammit's work and it is WAAAAAAAAYYYYYYY better than I could ever do!

 

[WFO Speedracer]

I am not up to speed on the carbon fiber as of yet,something tells me because of the materials costs the learning curve will be steep.I will be venturing off into carbon fiber a little later this year when I am making more money.

 

[dbrutherford]

Here is the the stock oil tank I want to mold the carbon tank off of. The two nipples will need removed and I would like it squared off where the filler neck is.

 

[WFO Speedracer]

Why not fiberglass ,either way that will be a tricky part though because it has to split and be waterproof.

 

[shawn_NJ]

DAVE! Just install your damn motor for Pensacola! LOL!!! I am finishing up on my 2nd X2 motor this week, so I can bring 3 X2's down for the ride. (Because one will die)....:Banane35:

 

[dbrutherford]

I hear ya Shawn, it won't be done before P cola though... I have all summer to ride, I want it done right. Genius cannot be rushed!

I will be making it out of fiberglass with just a layer of carbon. There will be a plate inside for the eklectrics mounted to. There will be another glassed into place to be the support/mount for the lid. Lid till be held down by either several bolts or some quick connectors of some type. Don't worry you guys WILL WANT ONE!

Here are somer pics of an R Pot carbon fiber box I have. It is too big though size wise to fit in the engine compartment anywhere though...

 

[shawn_NJ]

Convert to 650 electric. No big ebox needed and much lighter flywheel...lol

 

[x2skier]

How about a bracket attached to the front of the fuel tank to mount the ebox to? I seen something like this on legdrag.com (I think) for mounting total loss components for the SJ.

You can also modify the cases for 650 electronics without tearing the motor down. Any machine shop with an upright mill can do this OR get a die grinder and do it yourself.

 

[dbrutherford]

How about a bracket attached to the front of the fuel tank to mount the ebox to? I seen something like this on legdrag.com (I think) for mounting total loss components for the SJ.

You can also modify the cases for 650 electronics without tearing the motor down. Any machine shop with an upright mill can do this OR get a die grinder and do it yourself.

I paid too much to dremel the cases myself and I am not tearing it apart yet. Everyone that says you can do themselves doesn't like to have things the same quality as I do. I had Group K do a 750 engine years back for 650 electrics and it was perfect. I didn't send the stator with the cases and they called and asked for it to make sure it was done right. So two things going on here, stators new are not cheap and neither is a Jetinetics flywheel which I would run if I was using 650 electrics. I already have the Jetinetics. Not that I am an advocate for Group K just it was done the way it was supposed to be done. If the cases were machined, then I would probably run total loss. If I am going to spend money on an ignition, I will run an enhancer, an advent, or total loss.

I would just mount a custom ebox to the front of the cylinder using the pipe bracket/throttle cable mount but I am worried about vibration being a problem. The old PJS Viper engines had an ebox sinillar to this.

I am just saying "what if" and trying to design/develop a new part. I encourage all other ideas and I have a few others about this problem. One is to mount the electrics out in the open on a flat plate like some people do for total loss. Another is to stuff them in a Super Jet box. Key is not to rush things and come up with the best solution. I have far too much money tied up to build a ski that isn't up to the potential I want it to be. I would rather be riding than wrentching. I have blown up enough skis in my day and know how bad it sucks to be skiless and broke!

 

[Scorn800]

I paid too much to dremel the cases myself and I am not tearing it apart yet. Everyone that says you can do themselves doesn't like to have things the same quality as I do. I had Group K do a 750 engine years back for 650 electrics and it was perfect. I didn't send the stator with the cases and they called and asked for it to make sure it was done right. So two things going on here, stators new are not cheap and neither is a Jetinetics flywheel which I would run if I was using 650 electrics. I already have the Jetinetics. Not that I am an advocate for Group K just it was done the way it was supposed to be done. If the cases were machined, then I would probably run total loss. If I am going to spend money on an ignition, I will run an enhancer, an advent, or total loss.

I would just mount a custom ebox to the front of the cylinder using the pipe bracket/throttle cable mount but I am worried about vibration being a problem. The old PJS Viper engines had an ebox sinillar to this.

I am just saying "what if" and trying to design/develop a new part. I encourage all other ideas and I have a few others about this problem. One is to mount the electrics out in the open on a flat plate like some people do for total loss. Another is to stuff them in a Super Jet box. Key is not to rush things and come up with the best solution. I have far too much money tied up to build a ski that isn't up to the potential I want it to be. I would rather be riding than wrentching. I have blown up enough skis in my day and know how bad it sucks to be skiless and broke!

That would be a step backward. The kawi box is far better than a superjet box unless you want it to leak. :trink26:

 

[dbrutherford]

You are a Kawie guy, it is blasphemey to me too!

 

[crammit442]

Here's what I did a few years ago. Worked fine.