Ok here is the promised update on the HP2 Sport/ S1000 Mirror mounts. I worked on this through the week trying to get it into aluminum from the plastic quick prototype piece that has evolved over the last few months. Didn’t have too many paying jobs, so this got more attention.
On the plastic piece the indents for the breakaway connection needed more attention. They worked but not as well as the stock S1000 ones did. Spent a lot of time hand machining and then transferring that to the CNC and now have them perfect.
The other bigger problem was due to the complex shape and angles the CNC could not get into the area where the upper arm meets the base. After 2 different aluminum tries, it came out with the correct dimensions but looked like a blob of metal. Might not matter much as it under the rubber cover but it sent me back to the drawing board literraly.
I decided to make it out of 2 pieces. The base and the upright and then screw and epoxy them together. This meant another complete drawing and program and was a little complicated to get the holes in the correct location through 2 pieces with the angles. What resulted was the mount that you see here. It works, and doesn’t look bad.
There is still one more prototype to go. The screws will be hidden and in blind holes (I think) and I want to change the angle on the base piece or move the detents clockwise a few degrees to move the mirror arm forward. At the angle it is which is the same as the S1000 taller riders (me) could use more adjustment. Hopefully that will happen next week.
They are installed with the stock mirror screws. I weighed the mirrors and the new mirror is 50 grams less than the original, so less weight but more leverage.
Then make sure all everything was in the CNC program so there are no manual processes and make one more left bracket. Mirror image the left program and make a right and see how it is. There was some thought to making a mold and making these out of carbon. I would need 2 molds and the cycle time would be twice as much as the mill. With the limited amount of these that will be made, it would not be worth the investment.
I will see how much time I have next week to get the next changes completed. Planning on taking some extra days off and head to Nor Cal and the Sierra roads and passes (all open now) with the little lady on the RT. Might drop in on the 49’er rally too.
