My new JH600

**TexasAggie** · 05-20-2010, 06:06 AM

DuPont Kevlar coating is very good. I am not sure how to get in China unless the spray on bed liner in a can? I guess you could bring some back to China that way.
DT

**bikerdoc** · 05-20-2010, 06:29 AM

Originally Posted by TexasAggie

sorry, I am too old and thick for this blog stuff. Thanks for confirmation

I can relate to that, though for me it's not about being technology illiterate, but rather that the internet and all of the functions available within it, can eat up a lot of time. Time that could be spent on other sometimes much more important and/or more worthwhile stuff... like riding motorcycles or.... ;)

**jape** · 05-20-2010, 08:20 AM

I have been looking all over the place for that stuff in Aus, seems to be available only when job done by a specialist or else in $300 profeesional packs. No spray stuff I have found but will keep looking as that is an excellent looking finish. I want to do my bike frame in it when I strip it, also my bike trailer. Glad you got the pics worked out T. Aggie, thanks and keep 'em coming mate, i enjoy these kinds of threads very much and I am sure AW doesn't mind our interest.

**Pfaelzer** · 05-23-2010, 06:09 AM

Hi there,

the CNC fork bridge is done and installed. See the progress here:

WHEELS AND TIRES - edited 05-23-2010

I'll be traveling to Vietnam next week so there will be not much going on referring upgrades. However, after next week I hope to install the new springs and play with different fork oils to see how the bike responds. I also bought a nice pair of black fork boots,which will go on the bike after my return.

Cheers,
AW.

**Pfaelzer** · 05-23-2010, 06:13 AM

by jape...I am sure AW doesn't mind our interest.

Hi jape,
surely I don't mind. This thread is about technical stuff related to motorcycles. Hope to see more things coming from others. I am interested in these coatings too but will be looking more into it later. By now too busy with other things.

Greetings, AW.

**moilami** · 05-23-2010, 01:36 PM

Originally Posted by Pfaelzer

...back to modification list.

Really impressive.

**Pfaelzer** · 06-05-2010, 04:32 PM

HI,

back again with a little different modification this time. Something I have been planning to do since a while: Making fiber laminated parts. I found a good chance to play around on the JH600. When riding off-road in standing position, it is hard to hold the bike with the legs, since the side panels are too wide below the seat.

Well, some guys solved the issue like this, functional but the looks is a bit questionable:

Since I happen to have some good tools and helpers on hand, I decided to approach the project a bit more detailed. Starting up with a 3D laser scan of the original panel. To do that, the panel needs to be covered in a white paint, which reflects the laser:

With the data from the laser scanner it doesn't take too long to create a nice surface:

Next step is to create a negative and a good mold design, which can be used for the mold to laminate the parts:

Some CNC milling and the mold is ready looking like this:

Now it is up to laminating. As usual I have to travel, so I ask my team here at the neighbors door to do a first trial. This company makes laminated pipes and I thought they had some idea about that. Well... it turned out they were rather used to "casting-lamination", which looks like this:

At least that exercise was good enough to do some "fitting tests":

OK, one more time... The mold had to be repaired and cleaned up after that and we needed to think about a different way. A friend in my company did laminated parts before, so we decided to ahead. Getting the resin and fibers was the first job. We decided to go for carbon on the visible surface and a kevlar mix weaving behind for more durability.
Well, I had to travel again, my team being quite motivated went ahead with the next trials and they sent me the following pictures...

Clean mold:

Carbon fabric:

Kevlar fabric:

Lamination work:

First part ready:

Fitting test:

Details:

The part is still rough, surface and fixtures need to be done. I am off to Korea for the coming two weeks, waiting desperately for more information and pictures from my team - wish really I could be up in Fuzhou with them in the garage. Well, now I hope you all will be as curious as me to get more pictures on this. Right?

UPDATE - August 23rd, 2010

While I was off to Africa and Europe, my team continued to work on the side panels. Here some updated images

The surface is actually shiny but it is hard to capture. It all looks pretty smooth now and of course the design is flattened in the area where the riders legs are reaching to the foot-pegs. The composite has a Kevlar layer inside and carbon fiber layer on the top. It feels quite solid.

Here the right side. I am not 100% happy with the design here since it looks a bit too large. By now I do not want to make a new mold for this side so we will think about what to do. On the photo the carbon fibers are much more visible than in reality. I thought it is nice to give it a clear coat to see the carbon fibers but it does not really fit perfect to the black tank covers. I still have the option to paint it just black.

Details:

Here a look of the bike in total, left and right side

Again, in reality the fibers are less obvious. We are looking now for a nice little design to spray over it, matching a bit more to the tank cover.

Riding position is surely improved, however, the seat is really wide and due to the wide frame design this cannot be improved more I guess. I will update later once the work is completed.

Cheers,
AW.

**moilami** · 06-05-2010, 04:50 PM

Originally Posted by Pfaelzer

Kevlar fabric:

Really impressive engineering, I am very much speechless here

If not thinking why you don't start up a small Pfaelzer's Hi-Tech Parts business. And fer sure please take more pictures. I was wondering have you got bored to enchance the bike because so long before the new update.

**jape** · 06-06-2010, 12:09 AM

Hi AW, impressive as always. What wonderful fun you have to relieve the pressures of work and travel !!!
Moilami, if you have those tools in the workshop you already own a hi-tec design parts business, might not be 'bike parts though! With AW's style and liking for matte black it is probably non-metallic Glocks.

Questions, not criticisms., I wonder why use Kevlar? Cheaper than all fabricated in carbon mat? Is carbon not the lighter material? And what are the flammability properties of that resin, is it not a bit close to the exhaust for safety? Did you consider a matching front kit to create a stealth profile for speed radar returns?