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Navigation Tower for XR rally bike

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Navigation Tower for XR rally bike Empty Navigation Tower for XR rally bike

Post  Guest Thu Dec 04, 2014 6:51 pm

Skidmarks and I have been talking about building a nav tower for the XR. Another guy from the UK also asked me to build him one while I was at it. So, I'm making his first (practice) before making one for Mark and myself. Thsi is what they look like when completed...
Navigation Tower for XR rally bike 20140702_182334_resized_zpsf53646b6

Mark will be using a different type of light, so his will be quite a bit different. More on that later. The UK guy will have this same set.
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Post  Guest Thu Dec 04, 2014 6:54 pm

First step was to go out and buy some big assed hunks of alloy, Type 6061 in this case...

Navigation Tower for XR rally bike A_zpsc8d77fc4

I'm using the terms alloy / aluminum rather than ally / aluminium as I'm an American, dammit.
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Post  Guest Thu Dec 04, 2014 7:00 pm

I already make the curved parts that go inside of the steering head and about 1/2 done on the outside part...then I broke a bit as I was rushing things. So, ordered new bits that should be here soon.  They'll look like this when completed..
Navigation Tower for XR rally bike MRS_zps76ab853a

The bigger part is either welded to the bike's frame like this...
Navigation Tower for XR rally bike 20140702_181251_resized_zpsa3d87f81

or else bolted on. We're going with bolts in this case.
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Post  Guest Thu Dec 04, 2014 7:04 pm

Bolted to the frame mount will be this part...
Navigation Tower for XR rally bike B_zps4c5a1041
Navigation Tower for XR rally bike C_zpsf91c5f1d
Navigation Tower for XR rally bike D_zps262b6dc1

I cut a outline on it so it will press fit into the rectangular aluminum tube. Very snug fit. I'll then mill out a valley along the joint line and then weld these two pieces together....
Navigation Tower for XR rally bike E_zpsa97aab4d
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Post  Guest Thu Dec 04, 2014 7:11 pm

On the other end of the solid block will be the rectangular aluminum, I milled a 1" wide slot so it will slip over the part that is bolted to the frame...
Navigation Tower for XR rally bike F_zps713f3d31


Last edited by Earache on Thu Dec 04, 2014 8:39 pm; edited 3 times in total
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Post  Guest Thu Dec 04, 2014 7:13 pm

So when stacked together, it should be in this order...

Navigation Tower for XR rally bike G_zpsb4af6286

I've yet to cut the longest piece of stock down - it'll be cut on the black line.
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Post  Guest Thu Dec 04, 2014 7:15 pm

Next, I'll drill and tap the attachment bolt holes and then work on taking some weight out of the parts by milling excess material away.

More as it happens....
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Post  Guest Thu Dec 04, 2014 9:43 pm

quality job nice
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Post  Guest Fri Dec 05, 2014 3:15 am

Mad Frosty wrote:quality job nice

Thanks!

I kinda stole the idea from a post on ADVRider where the guy had a part machined out of a single chunk of AL...
Navigation Tower for XR rally bike IMG_0407_zpsf7687a99
Navigation Tower for XR rally bike IMG_0408_zps25979c58
Navigation Tower for XR rally bike IMG_0415_zps5b1ef2f4

I liked the idea of a single piece rather than a bunch of pieces bolted together to achieve the same shape. But the machine time on that and the price of the AL proved to be cost prohibitive for mark and the UK guy. SO I did the next best thing.. mating the two pieces and welding them into one.


Last edited by Earache on Fri Dec 05, 2014 3:19 am; edited 1 time in total
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Post  Guest Fri Dec 05, 2014 3:18 am

Some of the towers for professional competitors get rather elaborate....
Navigation Tower for XR rally bike 7354910-origpic-e94d59_zps65460949

But we're going to keep things small & tidy for now. Something like this one...
Navigation Tower for XR rally bike Iainwants_zps54d02150

It'll be a vast improvement over what the UK guy is using currently on his XR...
Navigation Tower for XR rally bike Iainsbike_zps7df96599

and we'll stack the lights rather than have them side by side.
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Post  Guest Fri Dec 05, 2014 3:33 am

In for win sauce.
Please provide price estimate at your convenience.
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Post  Guest Fri Dec 05, 2014 1:46 pm

Crown Imperial wrote:In for win sauce.
Please provide price estimate at your convenience.

Hadn't really intended on selling them. Should have kept track of my time spent on making them, but I didn't.
If I were to sell them, it'd probably be around $200 - or about 1/2 that if the customer supplied the materials. I think I've spent right at $100 for the aluminum and plastic so far. Will probably have to spend a few more $$$$$ on stainless steel bolts to hold it all together.

I'd guess I'll figure out ways to make them faster and less expensively as time goes on. BY the time I make the 3rd one, I should be able to do it faster with slightly less materials. Less (smaller) material to start with means less machine time as well. Just need a bit of experience as I go.

Not much of an answer, but there ya go.
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Post  Guest Fri Dec 05, 2014 1:47 pm

Let me know what kind of equipment you want to put on your dash / tower and I'll see if I can work out a cheap way to do it.
Or, if you have a specific design idea, send me a detailed drawing (as detailed as you can make it) and I'll see if I can whip it for cheap.
I work in aluminum, steels, plastics and carbon fiber -so pick a material as well.


Last edited by Earache on Fri Dec 05, 2014 3:59 pm; edited 2 times in total (Reason for editing : spelling)
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Post  Guest Sat Dec 06, 2014 6:16 am

Earache, farking nice work bro!
Pls keep on it and pls keep posting here, love yer work! BRP smile
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Post  Guest Sat Dec 13, 2014 5:25 pm

That is some mighty fine craftsmanship!

what is the white plastic you have used for the frame and is that a mock up or will the frame also be made of plastic?
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Post  Guest Mon Dec 15, 2014 12:26 am

appleseed wrote:That is some mighty fine craftsmanship!

what is the white plastic you have used for the frame and is that a mock up or will the frame also be made of plastic?

I'm using HDPE (high density polyethylene) for the plastic. The pic is one I stole off of the 'net. Have yet to make that part, but it should be the easiest part to make by far.

The theory of using plastic is that is doesn't deform quite so badly in the event of a spill.It also transmits less energy to your electronics, etc. And, it's cheaper than aluminum sheet stock.

I plan on using black HDPE rather than the white shown in the first pic.
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Post  Guest Mon Dec 15, 2014 12:31 am

Pieces are made, just need to weld together and drill the mounting holes....
Navigation Tower for XR rally bike IMG_20141205_143827916_zpsf57933e6

Applied layout dye* so i could see where to drill the holes, but got sidetracked on another project and haven't got back to drill them yet. Need to get that done this week....
Navigation Tower for XR rally bike IMG_20141205_145737228_zps309ab62c
Navigation Tower for XR rally bike IMG_20141205_145745636_HDR_zps3af2689a



* only use red dye for Honda parts. Blue dye belongs on Yamaha parts Cool
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Post  Guest Thu Dec 18, 2014 10:23 pm

Earache wrote:Let me know what kind of equipment you want to put on your dash / tower and I'll see if I can work out a cheap way to do it.
Or, if you have a specific design idea, send me a detailed drawing (as detailed as you can make it) and I'll see if I can whip it for cheap.
I work in aluminum, steels, plastics and carbon fiber  -so pick a material as well.

I don't really have drawings or anything I could give. All I got are dreams. A full front end of this kind would obviously cost major dorrah but may there's a way to somehow incorporate a fairing and tower similar to the one in the pic into the 7 gal Acerbis tank.

Navigation Tower for XR rally bike 03pari1_zps5b29a5dc

Navigation Tower for XR rally bike 03pari6_zpsd142e44e

Navigation Tower for XR rally bike 03pari2_zps27abaf33
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Post  Guest Fri Dec 19, 2014 1:50 am

Crown Imperial wrote:
Earache wrote:Let me know what kind of equipment you want to put on your dash / tower and I'll see if I can work out a cheap way to do it.
Or, if you have a specific design idea, send me a detailed drawing (as detailed as you can make it) and I'll see if I can whip it for cheap.
I work in aluminum, steels, plastics and carbon fiber  -so pick a material as well.

I don't really have drawings or anything I could give. All I got are dreams. A full front end of this kind would obviously cost major dorrah but may there's a way to somehow incorporate a fairing and tower similar to the one in the pic into the 7 gal Acerbis tank.

Making the tower portion is easy as shit. Can't really help ya much with the other stuff.Although I could mnake any mounts you might need if you're able to tell me exactly what you want.

I have an extra tower mount now - the guy from the UK that wanted one has bailed one me, so his parts are available. $50 in it so far, so anyone that wants it can have it for $50 + postage and I'll add any other parts to it at cost of the materials.

Here's what you'd get for $50 + postage:
Navigation Tower for XR rally bike IMG_20141205_143827916_zpsf57933e6

The parts that go into the steering head and the curved piece on the outside typically sell for $100-ish. So $50 for it all is a steal. Of course I'd drill it and tap it per your requirements so you can bolt it on.

The sides of the tower can be had in plastic or aluminum for about $65 more - slightly more if you need something really large. So the whole tower would run ya $115. I'll even powdercoat it in your choice of color as well.... even clear.
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