Jan 12

Jan 12, 2005

Sliding canopy progress.

Boy it's hard to get motivated in the winter! It's - 40 degree C (with wind chill) today and there's a very thick blanket of snow over everything. Progress is very slow and my motivation is low - but push on I will.

The first attempt to glass the pink Styrofoam was a disaster. The fabric pealed off the foam and the whole thing was a mess and way beyond repair So, I started over with a 3" thick piece of blue Styrofoam. (A speed bike shouldn't have pink on it anyhow).

I built an aluminum frame for the base of the foam canopy lid and fastened a good quality drawer slider to it. The 'female' side of the drawer slide is mounted to aluminum brackets that are fastened to the side walls at the back of the fairing top shell.

I chopped the lexan Zzipper fairing in half and carved out a foam rib so the two would mate together properly when the two halves of the canopy slide together.

I have not yet finished sculpting out the exact shape of the base, but it's pretty close - just need to do some tapering at the back, then I'll be ready to start laying on my fiberglass cloth. There is a gap between the bottom of the lid (sliding canopy) and the fairing top. I'm not sure how to deal with that... Maybe soft rubber weather stripping or something...

Here are some random photos of the work in progress:

First, I sketched out the general shape onto a 3" thick piece of blue Styrofoam
Rough shaping is done with a wire brush.
Here is a profile from the front showing that the middle is lower for better visibility, and the sides are higher to hold the lexan bubble.
This shows the tape-protected lexan bubble in place
I fabricated a frame to support the lid out of aluminum angle.
The angle is pressed into the Styrofoam, then glued into place using epoxy I tapped two holes where the drawer slider mounts to.
This is the male part of the drawer slider.
This shows the entire drawer slider assembled.
This picture is just to show off my aluminum welding. Periodically, I'll luck out with the perfect amperage and create some pretty welds.
Another gratuitous welding shot
The bubble will be cut in half and a glassed over foam rib will add support to the Lexan. I used an aluminum filler rod as a template for the inside curve of the bubble.
Here is the finished bubble rib.
The next 4 shots show the canopy sliding open
Here is a shot of the brackets that hold the female drawer slider
A view of the top of the drawer slider


TCR Do LIST:

1. Strut slot sliders - Simplify to a folding cover
2. Canopy Bubble - make a sliding convertible top
3. Front wheel well - Make glass version
4. Wingnuts for fairing mounts
5. Electrical - rechargable battery with a panel with switches for rear strobe and front headlight
6 Add a second front caliper brake
7. Make a portable wind trainer using the (mini-rollers)
8. Look into painting the fairing
9. Find a helmet that fits in the bubble
10. Add second brake

TOTAL distance on TCR1
866 km


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