R1100S Custom Triple Clamps Pre-Order
 

As some of you may already know, I have been messing around with new triple clamp designs for the R1100S (I know it seems like forever...) to cure what I feel is a flexy front end. This trait is usually only noticable when the bike is ridden hard and especially evident when trying to make rapid transitions from turn to turn. Many of you may not have even noticed this and are perfectly satisfied with the performance of the front suspension as it is. I am not, and will be making new upper and lower clamps for at least myself but wanted to get an idea if there is any interest in having more sets available when I get some hard price quotes. Obviously having just one set made will be extraordinarily expensive so it would be nice to be able to have at least five sets to get the price down. If there are any good machinists out there experienced with Solidworks and CAM, and would like to give me a quote, let me know too.

I started out my quest by designing a larger, two (two on each side) pinch bolt design upper clamp that was looking really nice. The only problem with it was that I had to lower the under the clamp bar position by about 1/4". I have had my handlebars in the 1/4" lower position for several rides now and it suits me very nicely. I also had Jeff Williams try this bar position out on his bike and he found it to be less than ideal. So, in the interest of being compatible to larger range of riders, I decided to design a single pinch bolt version that retains the stock bar height, under or on top of the triple clamp. The new clamp will still prove to be more rigid than the stock clamp and offer a new look to the bike as well. I retained the stock roundel too. This pic is just a graphic representation of the part and not the actual assembly.



http://forums.pelicanparts.com/uploa...1162400481.jpg



In the interest to gain an even less flexy front end than the new upper clamp would offer alone, I took a look at the lower clamp as well. It turns out that the lower clamp is by far the weaker of the two stock clamps and is likely the source of most of the flex I have been experiencing. The main cross member on the stock lower clamp is very thin at less than .600" thick over all. This is due in most part to the front fender mount and steering damper mount which severly limits the available thickness of the clamp.

A closer observation of the layout of the lower clamp assembly led me to see that I could gain some thickness and a great deal more strength by utilizing the space above the stock clamp as well. This additional structure will still allow clearance for the telelever arm and ball joint. In fact, when viewed from the front as assembled on the bike it will have a similar look to the new lower clamp setup on the R1200S. One of the best features of the R1200S that I noticed after test riding it was the signifantly more stable front telelever set up. I would be extremely satisfied if I could achieve at or near the improveved feel of the front end on the R1200S with these new clamps for the R1100S. I am expecting a big improvement in stiffening up the fork leg assembly on the R1100S with this new lower clamp alone. The new upper clamp will add some additional strength and more bling especially. At the very least, the new lower clamp could be used while still retaining the stock upper clamp, since I have retained all the stock geometry in both clamps. My goal was not to change any rake or trail handling traits of the bike, but rather to just radically reduce any flexing in the fron end when pushing the handling limits of the bike. Let me know if any of you are interested in these clamps. My purpose is not necessarily to make a profit on this but rather to be able to get the cost down so that these clamps can be an affordable upgrade to all of us. If I can get my own set cheaper by having multiple sets made, I'll be a happy guy indeed. Let me know if any of you have an interest in this, thanks.


http://forums.pelicanparts.com/uploa...1162400504.jpg

having executed an effort to fabric mo-betta parts for a machine and get costs to stabilize, have you determined what a run of these wold cost, top, bottom, both...and how does the price change if 5 get them or 10? thanks in advance. they look great, by the way. the top clamp is beautiful.

repoe3

Thanks, repoe. I am still waiting on quotes. I have the shop giving me prices on 1 set, 5 sets, 10 sets and 20 sets. I should have some info later today. I did have trouble getting some shops to even want to look at the job and the one that is quoting on it now has taken not gotten back to me in a week. I may have to still shop around a bit more, we'll see.

if you have the drawing file or can recreate it, try www.emachineshop.com. that was who i used to machine the alum. collar for the air intake kit for the aprilias. the cost, fab time, etc, is all generated online for you. in fact, the whole thing is handled online.

repoe3

CNC King
 

e-me YoYo, I'll run this past Oscar, he's the pro.
I'd need your final Solidworks file to get a real idea of run cost.

Rapid :cool:

You'll need to issue a recall so as to install the plug for the holes.

Scott, you know i'm in for a set (and the twin-bolt upper if possible) uness they're 1KUSD apiece...

Rapid, I sent you some drawings to your email. They are in a viewer only format but I can follow up with the actual parts if you need them for a more accurate quote.

ck, the holes are for looking at the cool lower clamp while you're riding. :)

Jony, I'm with you on the two bolt top clamp. It might be possible to have it made also since it has the same basic layout as the single bolt version. It all depends on the machinist's willingness to make the necessary changes for a small number of parts. It is definitely the one that gives me the biggest woody, even if it is probably total overkill and would only be suitable for the over bar mount and very few under bar folks. Here is a pic of the two bolt top clamp in black...


http://forums.pelicanparts.com/uploa...1162422054.jpg

Here is the single bolt top clamp in black also from the same perspective view as the two bolt version for comparison. I definitely like the black detail myself, and would be fine with the single bolt version too, which is most likely the only one that will be produced anyway.


http://forums.pelicanparts.com/uploa...1162423003.jpg

...if you wanted to dual clamp screw it and retain bar height you could raise the second clamp flange above the top surface....but that would require a s##tload more material and machining.
Best to use a flat plane on each, top and bottom, with one clamping screw.

yoyo, if you want another quote from a reasonable shop, e-mail the SLDPRT file to cmulhall *at* adcinc1 *dot* com. I can have one of our machinists give it a look and provide some I-know-ya discount.

Maybe not realistic, but a neighbor kid has run some things like this through their industrial arts class in high school. They have the computers and CNC machine and like to stretch their legs, so to speak.

BTW, I need the black ones!!!

Jony,
the two clamp will be stronger but your arms aren't long enough little guy.
Scotts 6'4'' with arms that hang to the ground.:D
Just IMO, your call my friend
jw

Scott,
count me in on the top and bottom clamp.
What ever color you want, as long as its not Pink,(sorry acid
;) )
cya
jeff

szell..szell
der wesier engle ist here!

Jeff, I run my bars above the clamp, with the 'dog's barbacks and a 4MM spacer underneath them.
the 2-bolt clamp will be just fiiinnne:)

http://www.pelicanparts.com/support/smileys/wat6.gif http://www.pelicanparts.com/support/...s/beerchug.gif http://www.pelicanparts.com/support/smileys/fles.gif http://www.pelicanparts.com/support/smileys/puke.gif http://www.pelicanparts.com/support/smileys/sleep.gif http://www.pelicanparts.com/support/smileys/nono.gif
http://www.pelicanparts.com/support/smileys/dom.gif

One more set here, Scott. Thanks. Color no matter.

Ditto here, Scott. One set in grey to match my wheels, please.;)

Just kidding!!:D

color shouldn't be an issue..I DO have a powdercoat booth....

You may try to locate a retired tool and die man. These guys usually have the equipment at their home to do most anything. Since they have very little overhead you can get a much better price and still get the quality you are looking for. My experience with machine shops is they wont do any custom motorcycle parts because they are afraid of the liability. This is why I make my own custom parts. Good luck. I would like to hear the felt difference with using both the top and botton double bolt design compaired to stock.