1handedluke Posted December 22, 2006 Report Share Posted December 22, 2006 right got some lever designs finished!, many thanks to Robin (Don't you just hate it when...) who did all the designing for me! and in such a sort time aswell! and basically now i've got to find a firm which will build it. i've got a few local firms who i need to get in contact with, but i was just wondering if anyone new anyone who COULD build it, of course it is going to have to be CNC'd!here is a few pictures!Leverbodythere is also a few more parts which i'm going to need, but they are all standard hope and magura parts!right anyone know anybody then?!? also does anybody know a rough estimation on the price of building something like this?thanks luke! Quote Link to comment Share on other sites More sharing options...
AdamR28 Posted December 22, 2006 Report Share Posted December 22, 2006 also does anybody know a rough estimation on the price of building something like this?I would have thought a few hundred quid at least for a 1-off. Quote Link to comment Share on other sites More sharing options...
nmt_oli Posted December 22, 2006 Report Share Posted December 22, 2006 (edited) Get in contact with some local engineering or manufacturing firms, and have a talk with there cnc programmers. I would be abel to take a desing like that into my uni workshops and get a one off made, but there machines are not suitable for mass production of them.Also, as an engineering student, for the love of god get some clearer drawings when you approach a company!The design looks great, but the drawings could be soo much better.dimensioning needs a fair amount of tidying up (no dimentions should be within the drawing itself- (see the lever blade for an example), sectional views of the resevoir/clamp piece would be very useful to clear things up, and to dimension too as its very bad practise to dimension to hidden detail lines.Im not trying to annoy you here, just giving you advise! keep the drawings to british std (BS8888), and people you approach will be impressed and more likely to help- as well as it being a clearer drawing.Edit: spelling Edited December 22, 2006 by nmt_oli Quote Link to comment Share on other sites More sharing options...
Walleee Posted December 23, 2006 Report Share Posted December 23, 2006 Yeh try getting a local college or university to churn one out for you,maybe get friendly with a student who can get friendly with a technician. And as had been said, I really can't make sense of those drawing's. I might be able to help you, but without knowing what's going on I really don't know.Any 3d model's to help me understand by any chance? Quote Link to comment Share on other sites More sharing options...
Davetrials Posted December 23, 2006 Report Share Posted December 23, 2006 waste of money?lever blade looks like a GU lever blade as well. EW Quote Link to comment Share on other sites More sharing options...
Bionic Balls Posted December 23, 2006 Report Share Posted December 23, 2006 have another look dave.... Quote Link to comment Share on other sites More sharing options...
Ashley Smith Posted December 23, 2006 Report Share Posted December 23, 2006 that will cost you an absloute fortune............ worth it if you have acess to machinery but if you are sub contracting then i simply would'nt bother.........the drawings and design are top notch though!well impressed!ash Quote Link to comment Share on other sites More sharing options...
RobinJI Posted December 23, 2006 Report Share Posted December 23, 2006 (edited) Hey, just to explain the situation here. This lever is not going to be made on any scale at all. It is absolutely a one off. All the lever is designed to do, it to activate 2 magura HS33 systems simultaneously off one lever. This is pretty much essential for Luke as his name suggests.Please don't go on about how it would be better to use one piston of twice the capacity, as we've already been through that in another topic. It would be more expensive as it would need a custom piston, and the likelihood of having a lazy whole break would be too high, meaning Luke would have to carry out constant maintenance, so not a lot of an improvement over just using one maggie lever with a hose splitter as he currently is.All Luke needs is a place to make this for him.The lever was designed on solid edge in 3D and then I took the orthographic drawings off that and dimensioned them, before sending Luke the files in Auto-CAD format. So as Luke has them as Auto-CAD files, they can be printed out as big/high rez as he could ever want.These are just initial drawings of it. If he needs any sectional views, or better dimensioning, or isometric views, all he needs to do is ask, and I can do it. I could send him the 3D files, but I'm not sure how many companies use Solid Edge, especially such an old version (7.0 I think), so I thought if I could give him some Auto-CAD files to show people, it might be a lot easier/cut the cost a lot. rather than them converting them.Edit: hope that clears things up a bit, sorry for the rant.Edit, Edit: Thanks for the help nmt_oli, I've been meaning to speak to you anyway, Prawn said you were taking mechanical engineering, at Portsmouth, which I'm looking at applying for very soon. Was just wanting to check out the coarse a little. Edited December 23, 2006 by Dont you Just Hate it When... Quote Link to comment Share on other sites More sharing options...
Walleee Posted December 23, 2006 Report Share Posted December 23, 2006 Can you save the 3d mocel's as iges files or stl files? if you can send me them and i'll have a look on solidworks....I wouldn't bother with manually writing a cnc program for that it'll take forever, have you any cnc cimulation software that can output NC for you? Quote Link to comment Share on other sites More sharing options...
RobinJI Posted December 23, 2006 Report Share Posted December 23, 2006 .stl I can do.As I mentioned above I'm only in my second year at college, I'm not really too sure about how this stuff works, I just know that I've drawn up some designs that should work, and that the right company should be able to use those designs to CNC something for Luke.I can e-mail .stls to anyone who might want them. Quote Link to comment Share on other sites More sharing options...
AdamR28 Posted December 23, 2006 Report Share Posted December 23, 2006 To make the lever more simple, reliable, and bring costs down, why not just have one piston in the lever? Quote Link to comment Share on other sites More sharing options...
Ben Cox Posted December 23, 2006 Report Share Posted December 23, 2006 Hey, just to explain the situation here. This lever is not going to be made on any scale at all. It is absolutely a one off. All the lever is designed to do, it to activate 2 magura HS33 systems simultaneously off one lever. This is pretty much essential for Luke as his name suggests.Please don't go on about how it would be better to use one piston of twice the capacity, as we've already been through that in another topic. It would be more expensive as it would need a custom piston, and the likelihood of having a lazy whole break would be too high, meaning Luke would have to carry out constant maintenance, so not a lot of an improvement over just using one maggie lever with a hose splitter as he currently is.All Luke needs is a place to make this for him.The lever was designed on solid edge in 3D and then I took the orthographic drawings off that and dimensioned them, before sending Luke the files in Auto-CAD format. So as Luke has them as Auto-CAD files, they can be printed out as big/high rez as he could ever want.These are just initial drawings of it. If he needs any sectional views, or better dimensioning, or isometric views, all he needs to do is ask, and I can do it. I could send him the 3D files, but I'm not sure how many companies use Solid Edge, especially such an old version (7.0 I think), so I thought if I could give him some Auto-CAD files to show people, it might be a lot easier/cut the cost a lot. rather than them converting them.Edit: hope that clears things up a bit, sorry for the rant.Edit, Edit: Thanks for the help nmt_oli, I've been meaning to speak to you anyway, Prawn said you were taking mechanical engineering, at Portsmouth, which I'm looking at applying for very soon. Was just wanting to check out the coarse a little. Quote Link to comment Share on other sites More sharing options...
AdamR28 Posted December 23, 2006 Report Share Posted December 23, 2006 As far as I can work out, the feature that houses the threads and chamfers, plus the threads and chamfers themselves, are gonna be much more expensive to manufacture than one simple piston. The surface finish required for the piston bores also ups the cost significantly - having two of those is gonna be un-necessary. You could also make the body retrofit a current lever blade, saving more cash. I didn't actually read that post though to be fair, I'm fully aware of Luke's situation (he's a customer of ours). I dunno, I'm just trying to suggest things to make it easier.Another idea: http://www.motorrad.magura.com/downloads/M...atalog_2007.pdfPart number, 0120438, Page 24 Quote Link to comment Share on other sites More sharing options...
Walleee Posted December 23, 2006 Report Share Posted December 23, 2006 .stl I can do.As I mentioned above I'm only in my second year at college, I'm not really too sure about how this stuff works, I just know that I've drawn up some designs that should work, and that the right company should be able to use those designs to CNC something for Luke.I can e-mail .stls to anyone who might want them.Send me the stl of the 3d model, my e-mail address is in my profile....You can make a CNC program from 2-D drawing's but it really is a pain in the arse. I'd imagine you want to do as much work as possible yourself (more directed at luke) to minimize the cost from the machining company.A CadCam program like delcam powermill would give you a simulation of the thing being made, you also need to consider how it will actually be machined and how it will be held in the CNC machine. Generally, you'd machine one face, then turn it over and machine the oppostie side, but because this has been machined there may not be any obvious means to hold it securley. It depends on the cnc machine really.Can you save IGES files? that's what you'd need to input the model into Delcam and the get your machining code from that.Like yourself, I'm no expert, but I don't think what is shown above would be quite enough, it's a damn good start though. I might also be able to do some stress analysis on it too for you it's really just a gimmick, but might point out an area where you hadn't thought of something.... Quote Link to comment Share on other sites More sharing options...
1handedluke Posted December 23, 2006 Author Report Share Posted December 23, 2006 right.... been doing some thinking about this, and there is alot of plus's and minus's maybe 1 piston would be easier to do, i wouldn't have to worrie about 2 TPA's or having 2 pistons made etc, but what size piston would i need? because i reckon 20mm piston would be way to big, adam did that lever you put the link up for have this piston? but im really after 1 finger lever, not some massive 3 finger moto brake. abit busy atm so i'll re-edit this post later(N) Quote Link to comment Share on other sites More sharing options...
fredrico Posted December 23, 2006 Report Share Posted December 23, 2006 Not really anything to with the lever, but to cover costs perhaps you could explain your situation and say you will quite happily advertise there company, might work Quote Link to comment Share on other sites More sharing options...
Dai the Socket Posted December 23, 2006 Report Share Posted December 23, 2006 How about you have a slice of shut the f**k up pie? Quote Link to comment Share on other sites More sharing options...
RobinJI Posted December 23, 2006 Report Share Posted December 23, 2006 I was saying that in advance before anyone mentioned it. As for a custom lever, me and Luke had agreed that the 2 cylinder design would be better. However, if he can get a ready made master cylinder, then it will probably cost him a shit load less, and be worth putting up with the disadvantages.Luke, by my calculations, the piston diameter you would need to run a single cylinder would be 19.799mm So one cylinder bloody close to 20mm would be near enough identical to the pressure exerted by the 2 standard magura levers. I hate to discard my drawings, but that would now be the obvious option. A piston stroke of 11mm sounds pretty close, and the leverage ratio of the lever of 1:7.2 is equivalent to adding an extra 6 or 7mm to the length of a normal maggie blade. So even though there is space for lots of fingers, you should be able to use one without a problem. Quote Link to comment Share on other sites More sharing options...
dave85 Posted December 23, 2006 Report Share Posted December 23, 2006 The only problem there is the price, the cheapy ones are 175 ish quid and the one ads indicated is 310 quid Quote Link to comment Share on other sites More sharing options...
Ben Cox Posted December 24, 2006 Report Share Posted December 24, 2006 ok im sorry for being a bitch Quote Link to comment Share on other sites More sharing options...
nmt_oli Posted December 24, 2006 Report Share Posted December 24, 2006 Get a design made up for a one piston version, and present both drawings when you find a manufacturer. they will know what is easier / cheaper to make on the machines.As tarty said, just getting the clamp/body made would simplify things a lot, and worth it unless you definately need a one off lever. a fresh products lever would be nice to fit, and is slightly longer than std giving you more leverage which you will need due to the extra brake.Dont you just hate it when: just pm me if you need any help with the drawings, im pretty competant at auto cad (need to aquire it though!) and most 3d software, although only really used ProDesktop and Pro Engineer a lot.Im also used to drawing a lot of stuff by hand- currently got coursework on it! orthographic, by hand to bs 8888! fun! so i can definately help you out there.If you want to have a chat with me about the course, give a opm or add me to msn and il be more that happy to give you any advise ect. Quote Link to comment Share on other sites More sharing options...
RobinJI Posted December 24, 2006 Report Share Posted December 24, 2006 Cool, thanks nmt_oli. I might get some plans made up to fit a standard blade and use one piston then. ok im sorry for being a bitch Sorry dude, I didnt read Adam@TartyBikes post above yours, I though you were just saying that my post was irrelevent/not what luke had asked. but it turns out you were sticking up for me in a way :$ Sorry. Quote Link to comment Share on other sites More sharing options...
NirZionTrials Posted December 25, 2006 Report Share Posted December 25, 2006 Hey,REALLY impressive Dont you Just Hate it When... its a good thing your doing.nice to see people helping out. and as for you luke, your wana of the coolest dudes out there, keep it up!wish i could help but i really dont know much on making that kind of lever... good luck guys! Quote Link to comment Share on other sites More sharing options...
RobinJI Posted December 25, 2006 Report Share Posted December 25, 2006 (edited) Cheers NirZionTrials I hope luke can get everything sorted.Anyone know all the dimensions to an 05 style magura lever? Or who could find them out?Edit: mainly the blade, like:The distance from the bars to the center of the pivot point?The distance from the pivot point to the center of the TPA wheel?The diameter of the little circular thing the TPA wheel sits in? The thickness of the lever blade at the Pivot point? Edited December 25, 2006 by Dont you Just Hate it When... Quote Link to comment Share on other sites More sharing options...
paolo Posted December 26, 2006 Report Share Posted December 26, 2006 Could you post a link to download the models, 3d models and bigger stills, please ? Quote Link to comment Share on other sites More sharing options...
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