FASTRAX ::PROJECT PRO RMK:: LOTS OF PHOTOS!!
- Thread starter FTXMOTORSPORTS
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Allllllllright! Now we have some progress. Recived the rough proto case from Robbie and it fits like a glove.
Notice the difference in the brake caliper mounting surfaces(the new case has the PRO RMK mounting layout)
Fit right into the oem casting like a glove!
back and front shots-this one is rough since it's whittled from a junk block of material that had a botched job already partially machined in it (hence the drain hole at the top of the case!)
and here is a shot of the IQ RMK, Pro Rush and the extended Pro case all together just for kicks.
Forward mounting flange detail...sorry about the glare...suckers to shiney!
So I'm pretty satisfied at this point. This case gives me a little over 3/4" of an inch of room at the tightest spot in the bulkhead(which is 3/8" tighter than anywhere else) WITH A FRONT COOLER (which the RMK doesn't have) and 8t 2.86 drivers in a 2.5" track. My final case will be set up for the Rush caliper and we are going to try to incorporate both sets of caliper mounting bosses if possible in the production case. Everything is headed back to Robbie for final tweaks and then we'll have a case to build with.
Notice the difference in the brake caliper mounting surfaces(the new case has the PRO RMK mounting layout)
Fit right into the oem casting like a glove!
back and front shots-this one is rough since it's whittled from a junk block of material that had a botched job already partially machined in it (hence the drain hole at the top of the case!)
and here is a shot of the IQ RMK, Pro Rush and the extended Pro case all together just for kicks.
Forward mounting flange detail...sorry about the glare...suckers to shiney!
So I'm pretty satisfied at this point. This case gives me a little over 3/4" of an inch of room at the tightest spot in the bulkhead(which is 3/8" tighter than anywhere else) WITH A FRONT COOLER (which the RMK doesn't have) and 8t 2.86 drivers in a 2.5" track. My final case will be set up for the Rush caliper and we are going to try to incorporate both sets of caliper mounting bosses if possible in the production case. Everything is headed back to Robbie for final tweaks and then we'll have a case to build with.
Yeah, you got me all figured out!
the clearance was with a 2.5 track-remember, this was a trail chassis and that cooler is pretty thick-they use it as a structural member for the bulkhead sides as well as the rear motor mounts (which I think is pretty sweet!)
now you know why it needed a drop and roll so bad!
The last report I've heard on 3" tracks is that there will NOT be any 15 wides offered this season-its an investment and demand thing.
By the way, while waiting on the drivetrain and tunnel side protos, I dug into the motor and have decided to build a stroked 700. I have already mocked up with a 70mm crank and 81mm cylinders and I like the way it comes out. Should augment the bottom end power a bit to let an already great turbo motor work even better. I will also be working in our latest turbo specific porting variation with this motor.
curt
We're making progress on the tunnel sides and have settled on this layout to give us the cleanest look, best fit and most strength. We work with thin fiberglass parts in the beginning so we aren't throwing away high dollar Carbon Fiber material every time we change our minds on design!
We've got the board angles where we like them and have decided on a "boxed triangle" where we join the tunnel to the tail at the board closeout. We did this for a few reasons: 1) a full length tunnel side is expensive to ship. 2) we'll only have to build multiple molds for the tail for different track lengths and can use the same running board/tunnel side mold for all variations. 3) with the double box design glued together we really increase the strength of this critical area where we've seen issues with many other tunnels and we do it with less dependence on the outer running board support tube.
with the footrest etc mocked up, all the fits are working out well so the next part out of the mold will be a carbon fiber piece that will become a permanent part of this sled.
I'll hold on to my idea for the board traction/snow elimination/suspension mounting piece until I have one completely done to show you...it's going to be sweet looking and super clean. We are going to capitalize on carbon fibers natural ability to resist snow sticking to it with this design to help eliminate some weight gain throughout a days ride.
I've also just about got the stroked 700(730) motor together with our turbo specific port layout so it will be ready to drop in once the tunnel is done and we can start mocking up the turbo for it.
Curt
We've got the board angles where we like them and have decided on a "boxed triangle" where we join the tunnel to the tail at the board closeout. We did this for a few reasons: 1) a full length tunnel side is expensive to ship. 2) we'll only have to build multiple molds for the tail for different track lengths and can use the same running board/tunnel side mold for all variations. 3) with the double box design glued together we really increase the strength of this critical area where we've seen issues with many other tunnels and we do it with less dependence on the outer running board support tube.
with the footrest etc mocked up, all the fits are working out well so the next part out of the mold will be a carbon fiber piece that will become a permanent part of this sled.
I'll hold on to my idea for the board traction/snow elimination/suspension mounting piece until I have one completely done to show you...it's going to be sweet looking and super clean. We are going to capitalize on carbon fibers natural ability to resist snow sticking to it with this design to help eliminate some weight gain throughout a days ride.
I've also just about got the stroked 700(730) motor together with our turbo specific port layout so it will be ready to drop in once the tunnel is done and we can start mocking up the turbo for it.
Curt
Thanks! Sorry so long for an update guys...its been poking along slowly. The chaincase is done and came out awesome-kudos to Avid for a beautiful piece and Robbie has been a great dude to conspire with!
Tunnel sides/running boards are finally getting laid up-we are finally happy with the molds.
Traction/skid mounting inserts are prototyped and final parts are being built.
I've got the mod done to the bulkhead(rear cooler top) to attatch the RMK coolers to the Rush.
Motor work is all done and we can now(in house) cut bearing clip grooves in the CFI case so the bearing thrust clip can be moved to the pto inside bearing where there is far more meat to handle the thrust impacts-we ended up building custom tooling and fixtures and this process will become part of every cfi 7/800 we build from now on-its much needed.
I've been slacking at this and I apologize! I will get progress pics up this week.
Curt
Tunnel sides/running boards are finally getting laid up-we are finally happy with the molds.
Traction/skid mounting inserts are prototyped and final parts are being built.
I've got the mod done to the bulkhead(rear cooler top) to attatch the RMK coolers to the Rush.
Motor work is all done and we can now(in house) cut bearing clip grooves in the CFI case so the bearing thrust clip can be moved to the pto inside bearing where there is far more meat to handle the thrust impacts-we ended up building custom tooling and fixtures and this process will become part of every cfi 7/800 we build from now on-its much needed.
I've been slacking at this and I apologize! I will get progress pics up this week.
Curt
Here are a couple pics of the finished stretched case set up with the Pro Rush caliper and disc...I added drain and fill plugs for convenience.
and we finally got the tunnel side molds prepped and pulled out one quick carbon piece to do a final test fit and figure out how we wanted to build the side extrusions-this one was fabbed from scraps but will give you the general idea-
So , we are finally done with working with crude development pieces and scraps now! The next pics you'll see will finally be production parts assembled on the chassis-since this chassis "glues" together, I'll walk you through the prep and application steps of the bulkhead and tunnel assembly involving the glue.
Also, the motor is fully assembled and the billet motor plate is getting whittled out in the next couple weeks-finally done with the design stages of it and it's a very nice piece that will give us all the strength we need to harness way beyond stock power. It will incorporate extra mounts to get the job done and we are ecstatic with the design.
and we finally got the tunnel side molds prepped and pulled out one quick carbon piece to do a final test fit and figure out how we wanted to build the side extrusions-this one was fabbed from scraps but will give you the general idea-
So , we are finally done with working with crude development pieces and scraps now! The next pics you'll see will finally be production parts assembled on the chassis-since this chassis "glues" together, I'll walk you through the prep and application steps of the bulkhead and tunnel assembly involving the glue.
Also, the motor is fully assembled and the billet motor plate is getting whittled out in the next couple weeks-finally done with the design stages of it and it's a very nice piece that will give us all the strength we need to harness way beyond stock power. It will incorporate extra mounts to get the job done and we are ecstatic with the design.
Its coming, its coming! I'm as impatient as everyone else but we are working with some partener shops this season and we don't always work on the same time frames (we all have other day to day projects to pay the bills!) Here's a couple pics of the traction/skid frame bracket mocked up for ya!
This design allows us to keep most of the aluminum under the running board. The smooth finish on the carbon fiber works well to keep snow from sticking to it (unlike bare aluminum) so we wanted to keep as much of the c/f uncovered on top of the board as possible. This piece also incorporates the front and rear skid frame brackets built in and we have done the home work to insure that the brackets are placed properly and are big enough to work with most common stock and aftermarket skids.
These pieces will be bonded to the running board/tunnel side with minimal fasteners similar to how the bulkhead is assembled.
This design allows us to keep most of the aluminum under the running board. The smooth finish on the carbon fiber works well to keep snow from sticking to it (unlike bare aluminum) so we wanted to keep as much of the c/f uncovered on top of the board as possible. This piece also incorporates the front and rear skid frame brackets built in and we have done the home work to insure that the brackets are placed properly and are big enough to work with most common stock and aftermarket skids.
These pieces will be bonded to the running board/tunnel side with minimal fasteners similar to how the bulkhead is assembled.
Killer work Curt...
Hope you let me squeeze the throttle on that one this year.
IMO,
Hard coat anodize (Type III) those traction ribs and RB edges.
Use the teflon impregnated type III... snow wont stick... neither will adhesive, but you can just grind it off where it meets the carbon.
Hope you let me squeeze the throttle on that one this year.
IMO,
Hard coat anodize (Type III) those traction ribs and RB edges.
Use the teflon impregnated type III... snow wont stick... neither will adhesive, but you can just grind it off where it meets the carbon.
T
Thunderguy BOOSTED
Well-known member
hows it coming on this bad boy???
Yeah, I've been hung up with other customer projects and haven't made any more progress yet-it'll probably my usual thrashfest to finish it up before our show here...should have more progress for ya maybe the end of next week!
Curt
Curt
T
Thunderguy BOOSTED
Well-known member
KK thanks Curt!! ( even though i dont like poo this is a SWEET SLED BUILD)
Cheers
Justin
Here's a few pics of things to come...most of the pieces are rounded up and we'll begin assembling the old girl in the next few days!
T
Thunderguy BOOSTED
Well-known member
I REALlY REALLY like that U-cooler
Well, we're making progress on the old girl-finished pulling the bulkhead apart , cleaned up the old glue and re assembled the coolers and bottom panel with fresh adhesive in preparation for the tunnel sides.
a little scraping and a heat gun removes the adhesive easily.
After paying attention for a change...it appears that this adhesive releases easily at about 150 degrees-a light prying force is all it takes to know if it has released or not.
here are the removed sections ready to clean and assemble.
Bottom plate and cooler after fresh adhesive and assembly:
The final tunnel sides are fitted, drilled and ready to assemble finally! we are finishing the pto side extrusion and will be assembling the tunnel over the coming weekend.
In the meantime....we've finished designing and building our Billet 6 mount Pro motor plate--this will be the answer for all of you turbo and big bore guys when the stock mounting system has problems...
And we've gotten a good start to the turbo system-we are working with HM turbos again and using Shanes proven components including the liquid intercooler system he pioneered several years ago. The Pro RMK won't have a bulkhead cooler to utilize this system but we have a way around that for you also! There will be a kit available from us and HM turbos to install the Rush bulkhead cooler into your Pro RMK if you want the benefits of rock solid consistent charge temps in all conditions.
motor mounted up and ready for turbo plumbing fab work to begin!
the Pro mounts the motor way lower than the IQ so they use angled boots to keep the throttle bodies out of the bulkhead.
tons of room in this chassis! the intercooler will hang from the hoop here...
Heres the pipe routing-fit like a glove even with the non-stock motor configuration
the internal stinger design leaves us lots of room for the turbo since the pipe is significantly shorter without the stinger hanging out...
most of you probably haven't seen this yet but this is what we do to keep pipes on turbos in one piece-its a custom made stainless flex bellows that we use to get rid of the unreliable and poor pipe to manifold sealing characteristics of most all current two stroke turbos-our design allows the pipe to go through its contortions due to heat cycles and still maintain a 100% pressure seal to drive your turbo. Allowing the pipe to "float" also alleviates the stresses on the pipe which helps keep the cracking issues away. we use stainless flanges to secure and seal the joint so no more broken spring issues and assembly is quick and easy with no bleeding!
turbine flange is fabbed and welded up- silencer is next and there is a ton of room for it!
nice short charge tube run to the intercooler...
Also got the rad new Avid drivers mounted up on the shaft
Sorry to post this all at once but we've gotten busier than ever and I'm losing my computer play time! I'll have more to post next week!
curt
a little scraping and a heat gun removes the adhesive easily.
After paying attention for a change...it appears that this adhesive releases easily at about 150 degrees-a light prying force is all it takes to know if it has released or not.
here are the removed sections ready to clean and assemble.
Bottom plate and cooler after fresh adhesive and assembly:
The final tunnel sides are fitted, drilled and ready to assemble finally! we are finishing the pto side extrusion and will be assembling the tunnel over the coming weekend.
In the meantime....we've finished designing and building our Billet 6 mount Pro motor plate--this will be the answer for all of you turbo and big bore guys when the stock mounting system has problems...
And we've gotten a good start to the turbo system-we are working with HM turbos again and using Shanes proven components including the liquid intercooler system he pioneered several years ago. The Pro RMK won't have a bulkhead cooler to utilize this system but we have a way around that for you also! There will be a kit available from us and HM turbos to install the Rush bulkhead cooler into your Pro RMK if you want the benefits of rock solid consistent charge temps in all conditions.
motor mounted up and ready for turbo plumbing fab work to begin!
the Pro mounts the motor way lower than the IQ so they use angled boots to keep the throttle bodies out of the bulkhead.
tons of room in this chassis! the intercooler will hang from the hoop here...
Heres the pipe routing-fit like a glove even with the non-stock motor configuration
the internal stinger design leaves us lots of room for the turbo since the pipe is significantly shorter without the stinger hanging out...
most of you probably haven't seen this yet but this is what we do to keep pipes on turbos in one piece-its a custom made stainless flex bellows that we use to get rid of the unreliable and poor pipe to manifold sealing characteristics of most all current two stroke turbos-our design allows the pipe to go through its contortions due to heat cycles and still maintain a 100% pressure seal to drive your turbo. Allowing the pipe to "float" also alleviates the stresses on the pipe which helps keep the cracking issues away. we use stainless flanges to secure and seal the joint so no more broken spring issues and assembly is quick and easy with no bleeding!
turbine flange is fabbed and welded up- silencer is next and there is a ton of room for it!
nice short charge tube run to the intercooler...
Also got the rad new Avid drivers mounted up on the shaft
Sorry to post this all at once but we've gotten busier than ever and I'm losing my computer play time! I'll have more to post next week!
curt
Just realized I missed your question! Yes we will be retailing the c/f tunnel sides and a few pretty cool variations of them for different applications.
curt
One more bit of info for ya! With the extended case AND a front bulkhead cooler, we have just under 4" of track room from the outer surface of a 2.86 pitch 8 tooth driver at the tightest spot in the tunnel (which is directly above the driver)
This case will allow big tracks with good clearance no problem and according to Justin its "super sexy"
This case will allow big tracks with good clearance no problem and according to Justin its "super sexy"
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