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| mat1600 | | Thunderbird |  |  | | Reg. Date | : | 06/03/2010 | | Posts | : | 8,596 | | Location | : | Bridlington, Democratic Independant State of Yorkshire, United Kingdom |
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| | Posted : 28 Sep 2012 - 17:49 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: DizzE) | | |
DizzE wrote:
, and he wants, time and material. Min. $500 - $800. |
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For doing what ? 
| My first natural instinct is to breathe. My second is to evade tax's.
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| DizzE | | Thor | |  | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 29 Sep 2012 - 04:04 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: mat1600) | | |
Just his hr. shop rate, doing stuff. It's OK, I've just about finished it. I just need a 16 mm end mill to finish up.
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| AlainD | | Set | |  | | Reg. Date | : | 16/12/2010 | | Posts | : | 164 | | Location | : | Nice, France |
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| | Posted : 29 Sep 2012 - 17:46 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: DizzE) | | |
DizzE wrote:
Oh, it won't die as an idea. But, ideas are not inventions, sadly, or I would be rich.
Still, however, this approach has got 1 critical path left to solve.
Alain's motor tests.
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At some point he will says that he has a electronic controller and most important, the software programming written, that will work.
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I have a quick update for you....
I have the 9800W 150kv motor and the PC board combo is due October 12th
Most of the software is already written, I still will have to implement the can thing
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| DizzE | | Thor | | | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 30 Sep 2012 - 04:14 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: AlainD) | | |
Very good. Thanks. Updates are always good to have. 
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| mag10 | | Set | |  | | Reg. Date | : | 05/02/2010 | | Posts | : | 485 | | Location | : | Wisconsin, United States |
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| | Posted : 01 Oct 2012 - 16:11 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: mat1600) | | |
mat1600 wrote:
If you have trouble with getting machined parts - give me a shout.
Really busy at the mo though. but could maybe slip stuff through.
You could try Mag10 too. He turns some good gear out - but not sure on his capacity/status .
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This is a very interesting thread (except for that little detour) I would be willing to help with some machine work if need be. I would have some time later this month, not that busy, but recovering from carpal tunnel surgery. one handed machine work is kind of slow!
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| DizzE | | Thor | | | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 01 Oct 2012 - 17:31 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: mag10) | | | Thanks, mag. I was trying to keep the detours to a min. And the other thread about mounting a C-15 is still a very
viable approach. It's all going to take some careful planing. I've spent hrs. in my little bench shop so far, and I think
I have an even more simplified solution I'm dialing in. My goal is to have something that can be knocked out on a
drill press and band saw, sanding and filing to fit. Just looking for a working prototype, at the moment.
Once I can get it bolted to the air box, I can pressure test the fitting before I cut the thru hole.
I figure I can pump it up with a bicycle pump to 8 psi. See if my sealing concept will even work.
That's the prototype.
Then once I perfect the measurements and publish a spec, folks with a vertical mill can certainly produce it
much faster than I can.
Stay tuned!
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| DizzE | | Thor | | | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 02 Oct 2012 - 05:04 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: DizzE) | | |
Nice. It didn't take our industrious trading partners very long to clone the Castle 2028.
Turnigy TrackStar 1/5th Sensorless Brushless Motor 760KV Link
$135.00
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| DizzE | | Thor | | | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 04 Oct 2012 - 02:29 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: DizzE) | | |
Gotta love this place. Silicon Intakes Link
An intake pressure tester. Woo Hoo! Don't have to make one up.
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| AlainD | | Set | | | | Reg. Date | : | 16/12/2010 | | Posts | : | 164 | | Location | : | Nice, France |
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| | Posted : 06 Oct 2012 - 16:25 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: DizzE) | | | 9.5kW Power board :
Will be on my desk by Thursday
The enclosure will be 200 x 90 x 70 mm
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| DizzE | | Thor | | | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 07 Oct 2012 - 01:37 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: AlainD) | | |
Very good. That is an amazingly small package. Will it need cooling fins or a fan?
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| DizzE | | Thor | | | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 19 Oct 2012 - 18:09 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: DizzE) | | | Ah well, I'm not a machinist, but I can see that it is an air sealing problem. Needs a form fit. Super expensive, tight tolerance.
So, I turn to another technique. Part against part, mold and casting. Much more Pro at this. And a real cool advantage if i can
pull it off. A pun!
- High temp, aluminum filled, fiberglass reinforced epoxy
- Embed the spigot flange in the casting
Prepping to take the master plug, gotta make it squared up with clay before I attach the molding box.
Spray on release compound.
Add goo. Keep warm over night.
| | Post edited by DizzE on 19 Oct 2012 - 23:42 |
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| DizzE | | Thor | | | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 20 Oct 2012 - 19:30 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: DizzE) | | | Got a good mold plug off the airbox. Reproduced those pesky angles and fillets. Covered it overnight, left a heater, and a remote temp sender.
Stayed 74-80 all night. Perfect. Won't work below 65F.
Cleaned it up. Then into the oven for 3 hours at 170 degrees.
While the plug is warm, melt in some clay by hand to fill and smooth any voids in the casting. Simple mold box made from
a food container with the bottom cut out.
Spray release compound and pour molding rubber (two part) Wood rails and hard point inserts are customary for attachment and a level bottom.
It also saves on molding rubber.
| | Post edited by DizzE on 21 Oct 2012 - 14:13 |
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| DizzE | | Thor | | | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 21 Oct 2012 - 20:19 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: DizzE) | | | Moving right along. Rough up the embedded aluminum part.
Mix up the stuff.
To the correct ratio. 100 : 8, by weight, in this case. add a healthy pinch of 1 inch long fiberglass, strand chop.
Fill the mold.
| | Post edited by DizzE on 21 Oct 2012 - 20:27 |
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| CornerBanger | | Jupiter | |  | | Reg. Date | : | 07/07/2010 | | Posts | : | 1,113 | | Location | : | Charleston, SC, United States |
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| | Posted : 23 Oct 2012 - 16:47 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: DizzE) | | | keep up the good work diz
| There are those who own and there are those who ride! 
2010 Thunderbird
2007 Kawi KX250F
2010 Kawi KX85 (My boy's ride)
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| DizzE | | Thor | | | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 23 Oct 2012 - 17:03 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: CornerBanger) | | | Thanks, bro. I'm just getting the epoxy to set, had a cooler night than I wanted and hadn't finished the set. I put in the oven at 175F and it MELTED.
Scrapped it back into the mold and it seems like it can stand the heat cure, later today.
The part will still need a bead rolled to make sure I can pressure test. Either $175 for a bench vise bead roller or get a little welder to make this tool.
Actually I can just use J.B. Weld epoxy to attach the exhaust bracket and washer to the grips.
| | Post edited by DizzE on 23 Oct 2012 - 17:22 |
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| DizzE | | Thor | | | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 24 Oct 2012 - 18:11 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: DizzE) | | | OK, making progress. I'm sure I have a part now that can stand, as a prototype for the pressure test.
Took 48 hrs to cure, so low over night temps defeated my cure time. But, it went. The fingernail test means you can't
dent it. 2 hrs at 175 F. then 3 hrs at 300 F. It's hard like a rock, but still workable. Did a little bit of rasping for the
photo. Haven't squared up completely, and it fits great.
Will use M5 x 4 bolts with Ny-lock nuts on the outside.
| | Post edited by DizzE on 24 Oct 2012 - 21:29 |
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| DizzE | | Thor | | | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 27 Oct 2012 - 04:23 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: DizzE) | | |
Moving along, some stuff got here.
The mount will be part of this U-channel blank. Maybe get 2 mounts. We'll see.
And the pressure test rig. Yeah!
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| DizzE | | Thor | | | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 29 Oct 2012 - 17:24 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: DizzE) | | | Well, a successful weekend on this project.
Air box adapter sealing test was GO, but only after a few iterations. I went back to M6 bolts, and just a small cork gasket on the land, only. And a lot of sealant.
For these static tests, I finally rigged a blow tube for the Mark I, lung pressurizer. Much easier to check if it can hold anything at all.
Finally I got it to hold and put the hand pump on. 10 pound, good to go.
I cut the U-channel in half and broke the band saw blade toward the end of the cut, finished with hacksaw.
2 coat of layout fluid, a life size print of the C-15. Yep, that fits. The electric motor, again is the pepper jar.
The blue lid is the saddle the electric motor will sit in. The Channel will be a heat sink. That thermo-connects the motor to the blower.
The blower is oil cooled so, now the motor is oil cooled as well, in theory.
Now I have to sculpt the mount and remove much of it. Then figure the way it attaches to the bike.
Alain will get the Power board and the regulator input, battery status indicator, etc solved.
All that will be left is to seal the air box box free air intake at the filter, when the blower pressure comes up.
Alain says he might have seen a part for that.
So, success so far. It is looking doable.
| | Post edited by DizzE on 29 Oct 2012 - 20:12 |
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| edbob | | Chaac | |  | | Reg. Date | : | 04/04/2012 | | Posts | : | 931 | | Location | : | United States |
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| | Posted : 04 Nov 2012 - 16:30 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: DizzE) | | | Link
You may think this is cool.
| "You will ride eternal shiny and chrome"
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| DizzE | | Thor | | | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 04 Nov 2012 - 22:40 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: edbob) | | |
That is an interesting concept. Wow. Thought provoking.
thanks,
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| TraderVic | | Set | |  | | Reg. Date | : | 02/02/2010 | | Posts | : | 274 | | Location | : | Manahawkin, NJ, United States |
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| | Posted : 05 Nov 2012 - 13:19 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: edbob) | | |
edbob wrote:
Link
You may think this is cool. |
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Very cool. 
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| DizzE | | Thor | | | | Reg. Date | : | 12/07/2010 | | Posts | : | 3,141 | | Location | : | Sunnyvale, CA, United States |
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| | Posted : 11 Nov 2012 - 20:23 Post title : Re: Thomas Knight - Electonic SuperCharger ESC-350 (Re: TraderVic) | | | Some progress on the mounting bracket concepts. The U-channel was just too beefy. We don't have that kind of space.
But, it was fun to cut it up with the bandsaw. I used as a kind of totem to help me think. 
Pushing it around under the throttle bodies gave me the 3D perspective I needed. New idea! What if, etc?
First you got to bend it. 2.5 mm 6061-T4. Stiff.
Then stick on the template and cut it out.
Now I need to adjust the left side of the bracket to bring it in toward the throttle bodies about 1".
I'll just re-cut that side.
I have to leave enough room to get my hand, on the oil dip stick, and pull
it out at the angle under the electric motor. It will work. I already use a long neck funnel to fill the oil.
The Rotrex guy told me yesterday, the C-15 hub is only 30 mm, not the 70 mm for the pulley.
Gives more space. I couldn't stand it  so I bought the Castle 2028 motor clone from Hobby King.
$132
And I got a set screw flange for 8mm shaft. I figure I can bolt the flange directly to the C-15's hub.
It might need a rubber pad between the two. That depends on the start up torque. We will see.
Alain says is building the power board prototype and we will need to work the concept about
sealing the air box at the filter, when the blower come on.
Looking more viable every step.
| | Post edited by DizzE on 12 Nov 2012 - 03:08 |
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