What's mine is yours

[KChatham]

Hi all!

So I made a thread several months ago about some lowered handlebars I made for my bike and I was kinda wanting to make some money making just a few and selling them. That didn't really happen and it was because, like most parts we make, it's hard to turn around and make a lot of parts efficiently and cheaply for others (while going to college and working). Since I can't provide this service to any of you (for making any of the parts I've made for myself) I can make them available for you.

I will send all my solidworks part files, cnc code, and setup sheets related to the ninja 250 to any who want it via dropbox. I will include everything in a folder and share that folder with you. If there is an easier method to share these files let me know as I've never done this before.

These are the parts I have available so far.

Rear Set Adapters - extremely easy to make. If you don't have a cnc you can easily take the dimensions from the solidworks file and drill these holes with a drill press/hand drill and then using a grinder of some sort cut out the profile and file the edges. Moves the foot peg 1 inch up and 2 inch back.


"Silver" Valve Emulators (just made these this week) - more complicated part, requires a cnc mill and lathe. These are $170 from RaceTech, I made mine for $30 total including buying the spring and internal shim from RaceTech themselves.





Ninja Turtle Vector Image - if you have access to a laser cutter or vinyl cutter makes for a cool decal





Handlebar Risers - complicated part, requires a cnc mill. If you make your own handlebars too a welder will be required or perhaps you could have a shop weld it for you real quick as it only requires simple welding.



I hope some of you find this useful and I hope it helps this community. I've got several more ideas of parts I want to make (true clip-on handlebars/preload adjusters/levers) and these will be available as well when/if they get completed.

If you want these files and have a dropbox account (free) provide your dropbox email address


Disclaimer: These are prototype parts that I've personally designed and made for myself. I don't take responsibility for anything that happens with my part files, cnc code, ect... I am very confident in these parts though and believe they will hold up to street/track use so don't hesitate to try to make them if you are willing and able!

Questions are welcomed.

EDIT: More pictures can be found here: http://s1229.photobucket.com/albums/...20Engineering/

Enjoy!

[csmith12]

Whoa! Nice work Kyle. Thanks for sharing.

[alex.s]

you freaking rock dude. i am looking forward to getting my mill/lathe's cnc going. i want to make emulators

[Kevin2109]

Your the coolest person on this forum. I want the kind of tools you have

[00NissanNinja]

That is some awesome milling work
I better make some use of the CNC mill at my school before I leave there. As a matter of fact, gonna mill a new brake bracket for my hugger. Thanks for the inspiration!

[leed]

Man my school doesn't give us that kind of access. Me using the machines for this kind of thing wouldn't be 'for school' at that point. The only way I could is if I incorporated it into a project for one of my classes. These look really good though, and very good of you to share with others. For those of you who don't have access, you may consider confronting a machine shop with the files to see if they'd run it for you.

[massacremasses]

wow dude that is extremely generous.

Great contribution!

[KChatham]

Thanks for all the complements!

Here is the upload link for the emulator and risers:

http://www.megaupload.com/?f=SM9WKWAB - emulator
http://www.megaupload.com/?f=L4TKL3CO - Handlebar Risers
http://www.megaupload.com/?f=2QXRLCEQ - Stickers

Let me know if there is any complication with it.

I'm extremely blessed to have the access I do at my school. I joined a club (FSAE) my freshmen year and because I was always working in the shop I was able to get hired as a student tech to help run the shops. As a tech we get keys and access to them basically 24/7. So while most students can't have use the shops for personal use us techs can.

More to come!

EDIT: I added a link for the ninja turtle sticker. It's an adobe illustrator file. I some how lost my original file so I downloaded the image and edited to make it easier to cut out (using laser cutter or vinyl) so it might not be 100% like mine but good enough. In addition to the Leonardo ninja turtle I found/edited/shared the files for the purple and orange ninja turtles.

EDIT: EDIT: Also, just so everyone is aware, the solidworks files are 2011!

[00NissanNinja]

I am very disappointed my school ended FSAE just shortly after my freshman year 3 and a half years ago. I joined and then bam funding cut and it was over. I would say our school prefers school related things, but the guy who runs the machine shop is cool about letting people use the machines. I mean technically all the Mech engineers pay for the machine shop anyways.

Anyways great work man and thanks for a great contribution

[Alex]

Originally Posted by KChatham

Here is the upload link for the emulator and risers:

http://www.megaupload.com/?f=SM9WKWAB - emulator
http://www.megaupload.com/?f=L4TKL3CO - Handlebar Risers
http://www.megaupload.com/?f=2QXRLCEQ - Stickers

Looks like megaupload.com has been taken down today for good, if you need another place to store these let me know.

[KChatham]

Thank you Alex for that, I tried getting on today and was wondering why it wasn't working. I will need another place to upload these files. What do you have in mind?

[Alex]

You can add them as attachments right here, just let me know what the file extensions were so I can add that file type if necessary.

[KChatham]

Alex, the files extensions were:
.sldprt
.slddrw
.sldasm
.txt
.docx
.ai

Thank you

[Alex]

How large do you think the largest ones might be?

[KChatham]

The largest file is 3,188kb the second largest is about 550kb.

[Alex]

Cool! All attachment types have been added, and should have plenty of space.

[KChatham]

Here are my files for the emulators and then handlebar mounts. Let me know if everything downloads ok.

CNC Code: txt files
Word doc: setup sheets
SLDxxx: Solidworks files

[actionace]

Wow, such an awesome post. Info like this is what makes this forum invaluable. Only wish I knew how to do this stuff. My brother-in-law just started at SDSU and is a Mech. Eng. major. Maybe one day he can set me up

[shiftdrift06]

AHH those handle bar lower riser looks great. i want a pair!!!

[CZroe]

Amazing. I wish I had access to the equipment to use these. Anyone who does better make a few extra!

Thanks.

[CZroe]

How much would a shop likely charge to make these risers? Is anyone worried that the shop might take the designs and make more, selling them on eBay or something? OP deserves a cut!

Oh, and the one pictured above: Is it finished? I don't see how it tightens against the bar without the gap I see here:


A couple more things I'd like to see do to fluctuating/limited availability: Mirror and turn signal block-off plates.

Also, I tried current-gen mirrors and they don't thread on the stay/mount but they do fit through and can be attached with nuts on the other end of the bolts. When installed this way, I think that they are angled too far forward for the short stalks. If someone made an angled plate to bolt through could sweep them back a bit, I'm sure it would make some people very happy.

[psych0hans]

@KChatham Hey Kyle, thanks for the input, I think this was very generous of you. Will any of these parts work with current gen ninjas? Mine is an '11 ninja and I wanted to make my own rearset adapters, but with some more adjust ability. Can I use your current drawing and modify it for the same? Please upload the files for the rearset adjusters if it isn't a hassle.

[Monkeytofu]

Originally Posted by psych0hans

@KChatham Hey Kyle, thanks for the input, I think this was very generous of you. Will any of these parts work with current gen ninjas? Mine is an '11 ninja and I wanted to make my own rearset adapters, but with some more adjust ability. Can I use your current drawing and modify it for the same? Please upload the files for the rearset adjusters if it isn't a hassle.

Rearsets on the newgen and pregen are interchangeable I think. Lots of people use the newgen ones on pregen bikes so I think you could get away with using these risers.


Never saw this thread before, amazing work!

[Solunatic]

kchatham you are my hero. I'm most definitely taking cad/cam classes now, I never even considered that i would be able to design custom parts for my bike.


But now i have a decision to make... anodized black or red?

[CZroe]

I thought that I never make the "due to/do to" mistake but I see that I did earlier in this thread and there is no way to edit it. ARGH!

Anyway, I plan to use my SV650 OEM or EX250J Woodcraft clipons on my EX250F but we need some kind of block-off plates to occupy the strange space the stock risers leave on the triple clamp. These designs seem like a good place to start.

[CZroe]

I contacted a local company with this email:

Hello. Earlier this year a generous soul shared some Solidworks files he made with members of a particular online forum (Kyle Chatham AKA KChatham of ninjette.org). They are for making a few parts that fit an extremely common motorcycle (1988-2007 Kawasaki Nina 250R). Though the cost is reportedly significantly lower than similar commercially manufactured parts, none of us have the ability to make them as we all lack access to a CNC milling machine and the software required to use these files. I live in Newnan (Coweta County) so I figured that you might be able to help me, but there may be a bigger opportunity.

Personally, I really want a few sets of his “lowered handlebar risers.” Many others have expressed interest in these as well as his “valve emulators” for the front suspension (lathe also required). I see that you offer POD (parts on demand), which I think would be a great option for interested forum members. Assuming that it can be made cheaply enough to still be desirable, as new users discover this openly available option, another POD part could be made and sold. I’m also interested in having a design modified to make a much more simple block-off plate instead of a handlebar mount. Is this something you could easily do with these files?

In case you are concerned with liability in case of accidents, these would not be complete parts and the people using them would be finishing them themselves, thereby transferring responsibility for the DIY job to themselves (tapping the holes and installing 7/8” OD handlebar tubing and bar ends for the risers, ordering springs and shims to assemble the valve emulators, etc). Also, you would simply be the executor of their wishes by manufacturing it on demand to the specifications provided by the customer.

If POD does require the re-occurring demand to come from the same buyer, I may be interested in being that contact. If a one-time production can be made cheaply enough, I’m still interested in getting a few made for myself.

The designer advised that four lowered risers can be made with 12" of 6061, but I don’t know if that’s four left/right sets or four total (two sets). Though the valve emulators are significantly smaller, they are more complicated with more operations. He said that 6061 is industry standard for aftermarket motorcycle parts, so I assume he used it for the valve emulators too, which he says cost him $30 after ordering the spring and shim from an over-priced manufacturer of suspension products. I don’t know if economies of scale allow you to match his costs or if you need to charge more to recoup your parts and labor, but there is still plenty of room to undercut manufactured products from the likes of RaceTech and Woodcraft. He gave the designs to the community, so there should be no issue with setting up a POD for us even if you are making a profit (you are charging for your services and not the parts). I would advise that keeping the cost low should still be a priority so that the community doesn’t shop around for other providers.

Personally, I don’t want to pay more than $60 for a set of handlebar risers or $50 for valve emulators, but I don’t know what other people are willing to pay and I’m not a racer (racers are more interested in valve emulators). I believe that most people would want to recoup their own costs by ordering extras and selling them as pre-made parts, considering how much higher the cost of manufactured products are (finishing and under-cutting by 33% should be easily possible).

Even if you are not interested in going further, please let me know. I can provide you with all the links and information. I look forward to working with you. Thanks!

-Julian Emmett Turner

I emphasized ordering multiples and extras so that they will keep the costs low (economies of scale). Also, the 20-year fitment should go a long way to emphasizing potential demand. I probably should have mentioned that they are commonly used as training/learner/beginner bikes and, thus, are often dropped and, thus, are in need of replacement handlebars more often than most bikes.

Hopefully, we can set up this "Parts on Demand" thing so that we can all contact them when we want one made.

Thanks again, Kyle. I want to order a few because I have a couple EX250F bikes and I want to experiment. Also, I think it would help me sell the suspension and frame I don't need from my parts bike.

[CZroe]

Curious: It seems that the RaceTech emulators are the same part for the 36mm EX250F and 37mm EX250J forks. Would these also work with both? Very interested to know! Thanks.

[CZroe]

@KChatham
Traxxion Dynamix is local to me and I needed some fork work done, which is their specialty, so I asked if they can make the valve emulators and lowered handlebar risers. They said that due to high demand they have a $5,000 minimum for machining things, which I assume is on top of the cost of materials (YIKES!).

Because they specialize in making suspension upgrades and I have seen examples of them being used and recommended by the Ninjette community (here and here), I have a feeling that they would change their tune if you authorized them to make and continue making/selling them. We would still have the plans for making our own so your gift would still be just as useful, though I'm sure you still don't want to see people repeatedly profiting off your work without giving you a cut. That said, even if they were able to make just one and undercut RaceTech's price they'd still be profiting off your work. Is this possible? I'd love to see cheaper options for lowered risers and emulators for everyone but I don't think anyone on the forums has access to such machinery.

[WesleySnipes]

Bahaha Never thought I would see this on here Nice work Kyle! That Ninja is pretty sweet man!

[iplante]

Few questions. Pardon the newb

1. Those risers.. How similar are they to the woodcraft lowered risers?
2. You mention welding the bar. Not sure I understand why that is?
3. Can it be used with the stock bars, or with any 7/8 bars (ie:woodcraft)
4. I would like black risers. Would any coloring process such as anodizing or whatever make the risers "not fit" anymore?
5. Any idea how much a shop would charge to get these done?

Also, thanks for sharing!

[choneofakind]

Bump on this thread since I've seen a few new members post about suspension upgrades/racing/etc.

Next semester I'll be taking a course called Experimental Methods. Basically we get to get a lot of shop time and play with the CNC tables/lathes/etc. I'll be making a set of these emulators in my spare time with help from the shop guy.

Big thanks to KChatham for giving these SolidWorks files to us. I took a look at them in class today and I have to say that they look great. I can't wait until I'm familiar enough with the shop to get a set of these made for myself. Not looking forward to the install in my forks, but I know it'll be worth it in the end.

[CZroe]

Please tell me that you'll be able to make a few extra sets emulators and the lowered risers for your forum friends.

[choneofakind]

No promises. I'm pretty sure that our shop guy won't be okay with me running a business out of ONU's shop

Don't forget that I'm going to be an ME junior. Next semester I'm signed up for 16 credit hours, I'm recruitment chair for my fraternity colony (...which is going for our charter second semester.), I work 10 hours a week on campus, and I've been recruited for the concrete canoe team because they need help badly. I also average 80-100 miles a week on the road bike while the weather is nice out and 20-25 miles a week running once it turns sour. I don't have a lot of free time. Also remember that I have to learn how to use the machinery before I take on personal projects. It will take me all of fall semester just to get one set of emulators done for myself.

[WesleySnipes]

Man you have too much on your plate @choneofakind. And you have to weld the end of the bars because he just uses bar stock which is pretty much just a piece of hollow aluminum rod.

I will be putting these emulators in my ninja with some racetech springs should feel pretty shnazzy.

[choneofakind]

Too much? Never. Until the gpa starts tanking, I'm going to keep myself busy. I have to do something or else I go stir-crazy. Plus being busy makes the rare lazy days taste that much sweeter.

Welding is out. I don't know how to weld yet either.

[WesleySnipes]

Keep yourself busy by dropping out and working at MC'D's yoh cause then you gotta work all the damn time to support your unborn twins and ho of a wife.

Nahh but seriously goodluck with welding and machining it sucks...but the end product is nice after the 100th time maybe...nahh seriously you will enjoy machining welding not so much especially Alum Tig that **** is hard. I look forward to seeing some emulators! I would start with those rearset brackets because they are super easy and the placement is nice.

[choneofakind]

One step ahead of you. I bought rearset adjusters 2 seasons ago. There's a link to my mods blog in my signature if you're ever curious.

[WesleySnipes]

Well mrhrrahrhar come race me bro. I'm even faster cause my rearsets are made of helium filled unobatanium which actually reduces the weight of the bike by 15lbs.

[CZroe]

Originally Posted by choneofakind

No promises. I'm pretty sure that our shop guy won't be okay with me running a business out of ONU's shop

Don't forget that I'm going to be an ME junior. Next semester I'm signed up for 16 credit hours, I'm recruitment chair for my fraternity colony (...which is going for our charter second semester.), I work 10 hours a week on campus, and I've been recruited for the concrete canoe team because they need help badly. I also average 80-100 miles a week on the road bike while the weather is nice out and 20-25 miles a week running once it turns sour. I don't have a lot of free time. Also remember that I have to learn how to use the machinery before I take on personal projects. It will take me all of fall semester just to get one set of emulators done for myself.

Totally understand. That's why it'd be something you do for "a few extra for friends" if you could.

Originally Posted by WesleySnipes

Man you have too much on your plate @choneofakind. And you have to weld the end of the bars because he just uses bar stock which is pretty much just a piece of hollow aluminum rod.

I will be putting these emulators in my ninja with some racetech springs should feel pretty shnazzy.

Actually, I always thought that was a strange and useless step. Even Woodcraft's clip-ons don't have those threaded inserts welded into them. Neither do my Suzuki SV650 clip-ons (there was a bit of rubber left in one of them). Most bike makers don't use threaded inserts for the bar ends and so universal bar ends that expand to fill the whole tube are cheap and plentiful. Just take a look on eBay!

I even bought some that were supposedly specifically for my 250 but I had to toss the expanding cylinders and thread the bolt in directly without the threaded cone spreader piece. Actually, I kept the expander pieces around and now use them on my Woodcraft bars. I later got some universal bar end mirrors that worked the same way but the expanded diameter was slightly too thin get tight without a bit of rubbery tape (used electrical tape).

Even if you want to keep your Kawasaki bar ends, which are hard enough to remove without marring, there's always Kkim's DIY on using Kawasaki's bar ends with the Woodcraft clip-ons for "free." Should work just as well with here, no welding required.

Anyway, how do you plan to make them? Perhaps YOU could make a few extra? Pretty please?

[Solunatic]

OP hasn't been on here in almost a year, anyway I could get someones files for the rearset adapters?