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Dan posted:

Here is the design for the White cog, just got to figure out now how best to do the metal sleeve and bearing Suggestions and comments most welcome!
posted on: 22/03/2015 18:05:23

dave posted:

Bearing press
posted on: 22/03/2015 18:50:14

Dan posted:

Have managed to finish this off. Here it is printed out with the bearing/sleeve inserted: Will see how it performs on the road later when the rain has stopped I'll make the design file available to download at some point along with the other cogs so those with access to a printer can try these themselves.
posted on: 28/03/2015 15:00:26

Karl posted:

Hi Dan, good work. If I didn't know better I'd say you turned it out of a block of wood. Cheers. Karl.
posted on: 28/03/2015 15:25:33

Dan posted:

Thanks Karl. I ran out of my usual White plastic so had to settle for the Gold variety
posted on: 28/03/2015 15:35:50

Dan posted:

Thanks to Chas and Dave as well for sending me the cogs to help complete the design
posted on: 28/03/2015 15:36:36

Area51 posted:

I can't see a press fit being strong enough You may need a keyway broached into The gear and a new insert machined with A key but still you have done a great Job
posted on: 28/03/2015 18:49:43

dave posted:

Nice work Dan you tryied the small ones ?
posted on: 28/03/2015 19:22:47

Dan posted:

[quote=Area51;5416]I can't see a press fit being strong enough You may need a keyway broached into The gear and a new insert machined with A key but still you have done a great Job [/quote] Hi Area, Thanks for the info. Not had any problems with it so far but we shall see. I think I understand what you mean, though I have no means to do machined stuff
posted on: 29/03/2015 17:07:43

Dan posted:

[quote=dave;5417]Nice work Dan you tryied the small ones ? [/quote] Smaller ones To increase the speed of the c5?
posted on: 29/03/2015 17:08:22

SINCLAIR C5 CHAS posted:

Hi I can have the alloy insert ones made to size but if you make them bigger you will go faster but you will loose power and that means more peddling.also you have to make sure that you can get a belt to fit I had a smaller one made up and at full speed you will only go about 6mph but it it will be better on hills Chas \:d/ \:d/ :-({|=
posted on: 29/03/2015 17:31:57

Karl posted:

Hi Chas.
but it it will be better on hills
Well, there's only one thing better than lot's of horse power, that's even more horse power.
posted on: 29/03/2015 20:03:37

SINCLAIR C5 CHAS posted:

Do you want to test one out Chas
posted on: 29/03/2015 20:41:03

Dan posted:

So here is a replacement bearing of the same type as the original I was going to use: http://www.bearingstation.co.uk/Products/Bearings/Roller_Bearing_Needle/Drawn_Cup_-_Metric/HFL2026-PREM And I was thinking of pressing these straight into the plastic and using some retainer fluid: http://www.amazon.co.uk/LOCTITE-BEARING-RETAINER-Bearing-Retainer/dp/B00AFT6FBE Has anybody got any experience of using this sort of thing? Otherwise will just look for a suitable sized sleeve with key like Area suggested
posted on: 19/04/2015 17:29:15

Area51 posted:

I don't think Dan loctite 641 will be any good as It is for metal to metal and I have use Many loctites which are good but I can't Think of one which will do metal to plastic
posted on: 19/04/2015 20:43:10

Dan posted:

Thanks Area, that makes sense. I'll look at getting some sleeves made up instead
posted on: 20/04/2015 06:50:25

Karl posted:

Hi Dan, would it not be worth trying one out? as the old saying goes "nothing ventured, nothing gained". It might just work out, and if it does you save a lot of addition work, cost, etc. If the worst comes to the worst you can still progress with the keyed sleeve idea. Having a special sleeve made will only push the costs up.
posted on: 22/04/2015 13:37:08

SINCLAIR C5 CHAS posted:

Hi Dan just been to my mates and he has put idea to me and it looks like it can be done .what I can do is to send you the prototype bar for you to have a go at making it fit in the 3 D cogs ...tight ... See what you think Chas
posted on: 22/04/2015 14:53:36

Area51 posted:

That looks a good idea Chas
posted on: 22/04/2015 15:40:21

Dan posted:

Nice one Chas, that'll do the trick By all means if you could send a prototype that would be great
posted on: 22/04/2015 16:57:24

Dan posted:

[quote=Karl;5500]Hi Dan, would it not be worth trying one out? as the old saying goes "nothing ventured, nothing gained". It might just work out, and if it does you save a lot of addition work, cost, etc. If the worst comes to the worst you can still progress with the keyed sleeve idea. Having a special sleeve made will only push the costs up.[/quote] Hi Karl, Yep I've had one of these in the C5 for the last couple of weeks using an original bearing and sleeve with no problems, but this sort of thing will need comprehensive testing. I don't plan to sell them, rather make the CAD files available to those wanting to print their own. We still need a replacement for the sleeve, as it's not something I've seen available anywhere, which I think Chas might have cracked now anyway. Thanks! Dan
posted on: 22/04/2015 17:02:38

SINCLAIR C5 CHAS posted:

Hi Dan all I can send you at the moment is the bar in the photo and if you can get it in your 3D printed cog that would be great then I can go ahead and get my mate to make one up with the center cut out to fit the bearing ... Bye Chas Ps can you send me you address as I have lost it again ...
posted on: 22/04/2015 17:22:20

SINCLAIR C5 CHAS posted:

Hi Dan the bar on its way .don't forget the invoice ... Chas
posted on: 23/04/2015 09:19:18

Dan posted:

Thanks Chas, received the metal hex bar and have hacked the design to suite it: It's tight, but does fit. Just waiting for the printer to knock 1 out to test it for real
posted on: 26/04/2015 15:33:32

Area51 posted:

Much better now Dan atleast the sleeve Can't slip now
posted on: 26/04/2015 15:53:43

SINCLAIR C5 CHAS posted:

Hi Dan looking great well done Chas
posted on: 26/04/2015 16:06:27

Karl posted:

Hi Dan, nice piece of work. You mentioned that you'll only be supplying the software, but are you going to supply the sleeves, or will you be leaving this up to Chas?
posted on: 26/04/2015 18:51:10

Dan posted:

Hi Karl, Thanks! I'm not sure at the moment we will work something out when we have one fully built and working
posted on: 28/04/2015 07:52:13

SINCLAIR C5 CHAS posted:

Hi Dan just had 4 sleeves cut take a look at them \:d/ :-({|= \:d/ I have one of my bearings fitted as you will see
posted on: 28/04/2015 18:07:50

dave posted:

Nice work Dan and Chaz
posted on: 28/04/2015 18:13:07

Dan posted:

They look great Chas, great work
posted on: 28/04/2015 19:18:23

Karl posted:

Hi Chas, do these have anything to do with B-Stocks?
posted on: 28/04/2015 22:05:18

SINCLAIR C5 CHAS posted:

Hi Karl what do you mean by B-Stock Bye Chas
posted on: 29/04/2015 07:01:19

Karl posted:

Hi Chas, sorry, it was a joke, but I thought you would have twigged it. The B-Stock has a double meaning, B-Stock, returned goods for resale, or a beestock, as the parts look like part of a honeycomb. Cheers. Karl.
posted on: 29/04/2015 12:41:01

SINCLAIR C5 CHAS posted:

Hi Karl no problem I did Google it and got the first meaning so I wasn't sure what you meant Bye Chas
posted on: 29/04/2015 16:20:23

Dan posted:

Thanks to Chas for sending the inserts. Here are some finished cogs: The smaller one has 60 teeth for use with 375mm belts. Will be testing them both at the weekend
posted on: 07/05/2015 18:43:00

SINCLAIR C5 CHAS posted:

Hi Dan they look great as always very well done just like the originals maybe even better as you can now have them made to measure \:d/ :-({|= \:d/ Bye Chas ..
posted on: 07/05/2015 18:58:15

Area51 posted:

Nice job Dan
posted on: 07/05/2015 19:50:58

dave posted:

Looking good guys
posted on: 08/05/2015 13:54:25

Ray1 posted:

Dan Looks very good printing quality, not sure I could achieve that. I assume PLA? What resolution is it printed at?
posted on: 08/05/2015 14:35:09

Dan posted:

Thanks for the comments guys. Regarding the resolution Ray, I just use the low res layer height setting and it comes out great. Yes, this is in PLA, that's the only material my printer can do.
posted on: 09/05/2015 10:50:17