My First 3D Printed Motorcycle Part

halfSpinDoctor

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I recently gained access to a Monoprice Voxel 3D printer, through the student engineering club where I am an advisor, and I have been looking for small, simple projects to get started learning about 3D design and additive manufacturing.

The cheap plastic handguards I bought off of eBay were missing rubber spacers in the kit, and when I had them installed the ends would rattle. I went to the hardware store to get a black nylon spacer or washer, but they didn't really have what I was looking for in the correct size and inner diameter, so I decided to make my own!

The part is extremely basic: 12 mm ID, 25 mm OD, 7.5 mm long. I sketched it up in OnShape, which is a free browser-based CAD software package. The free version lets you make as many parts or assemblies as you want, but they will be publicly listed and accessible.

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The print was done in PLA plastic. ABS will be more ideal, but I haven't gotten around to buying new filament yet. I used wide 3M blue tape and a coating of hairspray to get the part to adhere. It took me 4-5 attempts to get the head hight and temperature settings right to get good adhesion to the bed. The parts took 12 mins each to print:

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The result is a perfect fit! I left 1 mm of tolerance for the ID, and the spacers are snug but slide smoothly, and shouldn't rattle. With some neoprene washers on either end to protect the bar-end and throttle lock, and dampen out vibrations, the fit is snug with exactly the right length to hold the plastic guard from vibrating.

I may spray paint them black (or more likely redo them in black ABS), but for now I kind of like the red-orange look.

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670cc

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Very nice! I’m beginning to see the potential of a 3D printer.
 

sandman20

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Looks great Halfspin and I love Onshape. It works much like Solidworks so it was a good choice for me at home. 670cc, once you have a 3d printer you'd be amazed at the uses you will find for it. Be warned though, like motorcycles, they tend to multiply out of control :D
 

Janus

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Nice, the future has arrived. Now let's print some fairings that can be taken apart with bolts instead of tabs!
 

frog13

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HalfSpinDoctor.......what is the "ring" with letters on it, just inboard of the bar end weights? . TIA
 

halfSpinDoctor

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It wasn't too bad. The Kaoko replaces the entire bar-end weight. You have to remove not only the outer weight that sits on the end of the bar, but also the inner weight it screws into. This can be a little tricky, and is easiest to do if you first remove the right-side controls and loosen the throttle tube and slide it back to get at the tabs. See this thread for photos:


I had a fairly easy time doing it, but others have commented that it is very difficult.

The Kaoko is friction fit into the bar tube, with a clever design that drives a wedge outwards as you tighten the screw on the end to hold it in place. It comes with a sheet of copper foil that you can use as a shim, which takes a little trial and error to get right. They also suggest coating it with loc-tite to hold it, which I did not do and do not think is necessary.
 
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