TheSneeze
|
Here are my initial findings:
VISUAL INSPECTION
The parts have been through a vibratory deburr process (a lot like rock tumbling). This has smoothed out the exterior surfaces. Vibratory deburr process does not get inside holes. This is why there are more striations in the ID. With laser cutting, these marks are always present. The thicker the material, the more pronounced they are. Hardness of the material has an affect on the surface finish as well. The cup milled into them was performed after the vibe finish was applied. I found some of the cup milling had left a fine burr around the top edge of the feature. I filed down these burrs. Some of the batch I needed to scrap due to some bad striations that reduced the cross section of the part. Again, this is not uncommon with laser cutting. Overall the visual appearance was much better than I was expecting with my personal experience running a fab shop with a laser.
DIMENSIONAL INSPECTION
Although I was told the part fitment on the shaft would be tightened up more than the stock part, this did not happen. The double D hole is within .001" to .002" of the stock part. The play when installed on the shaft is the same as the stock part. This disappointed me, but is easily correctable with DBM's use of some feeler gage material inserted between the part and the shaft. The cup feature is right on in regards to the position in relation to the double D hole. I found the depth to be within a few thousandths, but I was using the depth gage on my calipers which has a flat end, trying to measure a round bottomed feature. Not the most exact method. I will try to use a better set up using my drop indicator with a round tip when I get to the strength testing. As you can see in the comparison picture (stacked), the overall length does not match the stock part - it is shorter. This has no effect on the part function in any way. It will still hold the return spring. Some of the striations on the inside of the double D hole needed to be filed down a little bit. The parts are hard, but not as hard as a file. I used a round/flat jeweler's file to do this. The striation burrs were just big enough to prevent the parts from sliding onto the shaft. Once removed, the play was discovered, and found to be the same as the stock part.
I will post up the strength test results as soon as I have the data. My plans are not to ship any of them until I am finished with all of my evaluations. I am very confident that these parts are a lot stronger than the stock ones, based upon the physical properties of the material alone. The strength tests will prove that. I ordered 25 parts, the shop made 30. After visual and dimensional inspections, I scrapped 5. Three for severe striations that compromised the wall thickness of the part, and two due to the fact they would not fit over the shaft (no matter how much filing was done). So there you have it. I absolutely will be running one of these on my hot rodded Savage motor. If anyone else wants to, just hit me up. If you don't, that's fine too. The money I have spent on this manufacturing run was worth it to me just to solve the slipping clutch issue that would happen on MY bike. If this will help out more of you, great.
I am open to comments and friendly discussion/questions. If you feel like being negative, just don't ask for one. Peace, out.
|
Pages: 
