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  1. #1
    The Mod Father
    Join Date
    Apr 2016
    Location
    Lisburn.,Northern Ireland

    Custom Japanese swingarm bobbins...

    OK....so in my additional 'Mods' thread I promised I would do a little creative machining last week as I was off work....and after decorating the kitchen for my wife I was finally free for a little lathe time..!

    I had intended to make a custom set of Swingarm spools/bobbins for a little while (and I wanted to incorporate a Japanese theme)...

    I like working in brass (my favourite metal) as it allows me to get a little intricate.....

    A strange quirk with the Kawasaki swingarm is that the location points for the spools differ slightly in that one is welded on further inboard that the other (right versus left) and as such this was catered for in the machining process.

    Anyway I trust the step by step photos will convey the story to completion..and this thread quenches your fix.


























































    Sent from my SM-J320FN using Tapatalk,
    Last edited by BG Wells; 08-23-2017 at 07:25 AM.

  2. #2
    Thread Hijacker
    Join Date
    Sep 2014
    Location
    Fun City so Cal. on the West Coast of our U. S. of A.

    Cool Re: Custom Japanese swing arm bobbins ~ good thing they don't spin . . .


  3. #3
    BadAss Hooligan
    Join Date
    May 2015
    Location
    Birmingham, AL

    Re: Custom Japanese swingarm bobbins...

    DIBS LOL

    WOW... your creatively is unbelievable! One of a kind those are outstanding but we've learned that's all that comes out of your camp

    Nicely done Brian

    Wayne

  4. #4
    BadAss Hooligan
    Join Date
    Jul 2015
    Location
    Melbourne, Florida....On the corner of "walk" and "Dont Walk"

    Re: Custom Japanese swingarm bobbins...

    Sick.
    ZRXOA #9877
    "IT'S NOT THE BIG THAT EAT THE SMALL..... IT'S THE FAST THAT EAT THE SLOW"
    2004 ZRX1200R-Silver


    Past Kawi's: 76 KZ900, 78 KZ1000, 80 Z1 Classic

    Off Brands: 74 Honda XR75, 80 Yamaha YZ250, 84 Honda 1100 Magna,
    95 Suzuki RF900R, 88 Suzuki Katana 1100
    Wish List: 74 Yamaha DT400

  5. #5
    Calamity Gil
    Join Date
    Aug 2009
    Location
    Niagara Falls, USA

    Re: Custom Japanese swingarm bobbins...

    Quote Originally Posted by Dirty Howie View Post
    Sick.
    As in,"I feel sick looking at Brian's workmanship"? Yeah, I hate to like his work too.
    ZRXOA membr #8704
    "It is not the strong but the responsive that survive."

    BOTM Feb '13

  6. #6
    Just call me Gordon
    Join Date
    Aug 2015
    Location
    Springbranch TEXAS

    Re: Custom Japanese swingarm bobbins...

    Stunning as usual Brian your craftsmanship knows no boundary

    NOV 2017 BOTM
    #9927

  7. #7
    President of the ZRXOA
    Join Date
    Mar 2012
    Location
    Pleasanton, CA

    Custom Japanese swingarm bobbins...

    They're too nice to use anymore Brian! You really gonna scrape them up with a rear stand?

    Beautiful work and fun watching how it unfolds in the pics.
    Arash (pronounced "our-ash")

    CAUTION - My forum posts may be worth what you paid for them!

    2005 Green RessuREXtion - Amateur 1224 & Six Speed Installation - Oct 2015 BOTM - Yamaha R6 - Aprilia RS250s

  8. #8
    Two wheeled FREAK
    Join Date
    Sep 2001
    Location
    NY - Between thought and expression...

    Re: Custom Japanese swingarm bobbins...

    Holy cannoli! You never cease to amaze me! Incredible detail and beautiful results!


    PM me for great prices on Öhlins shocks and forks!
    ZRX-1200 - 2001 #2 - 45,500 miles and counting
    Highly opinionated and somewhat twisted, or so I've been told.

    http://www.orientexpress.com + http://www.hudsonvalleymotorcycles.com - places where I used to work...

  9. #9
    President of the ZRXOA
    Join Date
    Mar 2012
    Location
    Pleasanton, CA

    Custom Japanese swingarm bobbins...

    The rotation bit is really trick Brian! Just awesome.
    Arash (pronounced "our-ash")

    CAUTION - My forum posts may be worth what you paid for them!

    2005 Green RessuREXtion - Amateur 1224 & Six Speed Installation - Oct 2015 BOTM - Yamaha R6 - Aprilia RS250s

  10. #10
    BadAss Hooligan
    Join Date
    Apr 2015
    Location
    Guyton, Georgia

    Re: Custom Japanese swingarm bobbins...

    You continue to amaze my mind with your creativity Brian. You took several common items and made something beautiful! Like has been said already I would not want to scar them up putting a stand to them!!

  11. #11
    BadAss Hooligan
    Join Date
    Sep 2012
    Location
    Bethesda, MD

    Re: Custom Japanese swingarm bobbins...

    How about some cylinder head porting!

  12. #12
    Bleeding Kawasaki since the 70's
    Join Date
    May 2002
    Location
    Charleston, TN -- bah-ha-wa-ha!

    Re: Custom Japanese swingarm bobbins...

    Purdy.

    SS
    For all the members we've lost - this board can only hope to help you live on in others. YTRAP, itchy butt, Gary1129, Mavwrek, Mitch#101 and all the others you are forever remembered.
    I have been to HELL. A loft with John T on one side and SS on the other That was a cataclysmic snore fest, weakening the tectonic plates Georgia rests upon!!!!
    YTRAP 2/23/05

    Quote Originally Posted by youngzrxer View Post
    Perko has a good point though....

  13. #13
    BadAss Hooligan
    Join Date
    Oct 2014
    Location
    Washington DC

    Re: Custom Japanese swingarm bobbins...

    Member # 10024 - 99 ZRX1100
    Les Coqs Sauvages - We travel not to escape life but for life not to escape us...
    "A little extra is never enough…too much is just right..." - KWICK

  14. #14
    President of the ZRXOA
    Join Date
    Mar 2012
    Location
    Pleasanton, CA

    Custom Japanese swingarm bobbins...

    I just noticed they are asymmetric. Neat.
    Arash (pronounced "our-ash")

    CAUTION - My forum posts may be worth what you paid for them!

    2005 Green RessuREXtion - Amateur 1224 & Six Speed Installation - Oct 2015 BOTM - Yamaha R6 - Aprilia RS250s

  15. #15
    The Mod Father
    Join Date
    Apr 2016
    Location
    Lisburn.,Northern Ireland

    Custom Japanese swingarm bobbins...

    Quote Originally Posted by Rustytools View Post
    Reminsent of some of the fine inlay work on my high end pool cues.
    Ok so although these custom made bobbins required a bit of work ....there was just something about them that kinda did not please me.

    I posted them up on another motorcycle forum for 'another opinion'....and although the vast majority were complementary....one member posted what I was already thinking.....and that was they were a little "Kitsch".

    I was never going to be happy having my own thoughts confirmed (despite the work I had invested)....
    So I decided to raise my game and re machine them..!

    This would be MUCH more involved than before...but ..."If a job is worth doing.,it is worth doing right.!"

    I still wanted to carry the Japanese flag theme...but tie in the Kawasaki colours..(easy to say in theory..but very complicated to construct)

    I am much more satisfied with the overall presentation now....and although I needn't cover the entire construction process (Having covered much of it previously) I will cover some of it in the accompanying photos.















    Sent from my SM-J320FN using Tapatalk
    "A change in behaviour begins when Jesus changes our heart "

    Carina Wells (Mum)
    RIP.

    April 2017 BOTM~2017 BOTY
    August 2019 BOTM..
    #10080

  16. #16
    President of the ZRXOA
    Join Date
    Mar 2012
    Location
    Pleasanton, CA

    Custom Japanese swingarm bobbins...

    Rev 2.0
    Arash (pronounced "our-ash")

    CAUTION - My forum posts may be worth what you paid for them!

    2005 Green RessuREXtion - Amateur 1224 & Six Speed Installation - Oct 2015 BOTM - Yamaha R6 - Aprilia RS250s

  17. #17
    All I Want To Do Is A Zoom - Zoom
    Join Date
    Jul 2008
    Location
    Worcester, MA

    Re: Custom Japanese swingarm bobbins...

    beautiful results
    There's nothing to fear but fear itself

  18. #18
    Mainely here
    Join Date
    Aug 2001
    Location
    Maine

    Re: Custom Japanese swingarm bobbins...

    You're one heck of a craftsman. Those things are beautiful!


  19. #19
    President of the ZRXOA
    Join Date
    Mar 2012
    Location
    Pleasanton, CA

    Custom Japanese swingarm bobbins...

    Top notch!
    Arash (pronounced "our-ash")

    CAUTION - My forum posts may be worth what you paid for them!

    2005 Green RessuREXtion - Amateur 1224 & Six Speed Installation - Oct 2015 BOTM - Yamaha R6 - Aprilia RS250s

  20. #20
    Just call me Gordon
    Join Date
    Aug 2015
    Location
    Springbranch TEXAS

    Re: Custom Japanese swingarm bobbins...

    DIBS



    Those are the shite Brian wow

    NOV 2017 BOTM
    #9927

  21. #21
    BadAss Hooligan
    Join Date
    Nov 2010
    Location
    Shiny Side Up ^

    Re: Custom Japanese swingarm bobbins...

    Utterly Amazing Fabrication Skills!!!!!!!!!!!!!!!!!!!
    Big Harry

    "As you swim the river of life, do the breast stroke. It helps to clear the turds from your path!"
    George Carlin

  22. #22
    The Mod Father
    Join Date
    Apr 2016
    Location
    Lisburn.,Northern Ireland

    Re: Custom Japanese swingarm bobbins...

    Quote Originally Posted by AV80R View Post
    Top notch!
    Quote Originally Posted by Deerslayer64d View Post
    DIBS


    Those are the shite Brian wow
    [QUOTE=Big Harry;4761602]Utterly Amazing Fabrication Skills!!!!!!!!!!!!!!!!![QUOTE]



    Thanks so much...

    The only thing left to do is shoot them with some 2 pac clear coat suitable for Aluminium and other non ferrous metals..

    I called with them to my friend Phil Smith (who painted my bike) of 'Crazycustompaint.com' today to get some advice on this and he kindly gave me all the 'materials' (and tuition) for free.!

    Two perfectionist nutcases together in his workshop bouncing ideas of each other..? (It's what Saturday's are made for.!! Lol)

    Here are some 'in progress' shots....(and one of the Joey Dunlop tribute helmet he is airbrushing).......now this IS a guy with incredible talent.!




    The most important thing in making something intricate is figuring out how to 'hold it' during machining......here is one of a pair of brass 'holders' who's only puropse is to have the 'inlay' bonded to during the initial machining process.... (they will Not be part of the completed bobbins....)



    Illustrated are two carefully selected sections of Acrylic which will ge used for the initial inlay background..



    The two 'internal' lime green discs are machined as a basis from which to build upon.... (their 'outside' diameter is critical and predetermined during the design process by me)



    Two Aluminium "machining holders" are made to allow machining of the black Acrylic which will mate to the Lime green 'core'..





    Machining the black Acrylic it is critical the 'inside' diameter matches the 'outer' diameter of the Lime green core...



    The brass backing plates of the bobbins have been recessed to accept the Acrylic 'inlay'... (machining these has been covered in the first page of this thread...



    The Black Acrylic outer discs have been removed from their Aluminium 'holders' via the 'flat' left on either side during machining for their removal process....
    They have now been bonded in position over their lime green cores which remained on their Brass 'holders....



    The freed up Aluminium holders now have white acrylic bonded to them for matching the white Japanese flag sections...



    Segments are removed via a slitting saw (60mm X143 teeth) and the 'work' mounted in the rotary table......I opted to go for 1/9th segment division this time (as opposed to 1/8th for the previous incarnation of these bobbins....on the first page)



    The 1/9th segments removed alongside their corisponding white counterparts to be fitted...



    The white 'flag' background segments now fitted along with a pair of 0.9mm brass separating strips now ready for further machining...

    The surface illustrated is infact the rearside as I am working in reverse for this project..



    Prior to further machining two sections of 10thou styrene sheet~plastickard were prepared to bond to the Acrylic inlay rearside surface...(without this the entire inlay would fall apart during further machining) as each part is now separate...)



    With the 10thou styrene sheet bonded in place to ensure the inlay stayed intact 'reduction machining' can now take place...



    The Red 'Rising sun' portions are now machined to 3mm diameter from thicker red acrylic rod to be bonded into corisponding predrilled holes in their respective 'flag backgrounds'.... (this process is covered on page one of this thread)



    Final machining is now completed on the various components...



    The rear of each brass backing plate has a variation in its respective 'spigot' (Right to left) to suit their mounting points on the Kawasaki swing arm...



    Machining all done the bobbins are awaiting two 'Kawasaki' lettering logos to be added for completion



    I had 'considered' entrusting these bobbins to a Trophy engraving company for the lettering process......however I opted not to as I would then have no control over 'spacing'...'font'...'consistency'..etc and one mistake from a third party would result in my work being completely ruined...

    After much consideration I opted to do the lettering myself and sourced a suitable sheet of 2.4mm dry rub down lettering in the Netherlands...



    After many tries (and failures.!) I finally got the lettering to a point where it was absolutely consistent and I was happy with....

    The bobbins only remain to be clear coated to seal everything in for protection...








    A lot of work for two little items that will almost certainly never be used and simply serve to mount to their respective location points on the swing arm..

    Nevertheless although I have made them fully functional...I will continue to use my paddock stand with its rubber 'cups' and raise the bike via this either in front of or behind these bobbins...

    Thank you all for your interest and kind comments..

    Stay tuned till next time,
    Brian.
    Sent from my SM-J320FN using Tapatalk

    Edit.....

    I had some free time over lunch...and I guess I still could still find one more little area to 'tweak' and that was their retaining screws/bolts.

    I sourced two replacement stainless steel Allen/hex recess cap head retaining bolts/screws.

    1@ M10x1.25 pitch..40 mm
    1@ M10x1.25 pitch..45mm

    The differential being to compensate for the longer versus shorter spigot on each bobbin back plate (left versus right ..as per the location points on the swing arm)

    Well I had custom machined everything else and I thought I'd change the heads on the rather plain screws to make them a bit more unique...

    The first thing is to machine the stamped 'nomenclature' from the front...

    Secondly the little 'curve' where the shank meets the rear of the head had to be machined out sharp so thread is no restriction for the rear of the head to interface perfectly into the recession on my bobbins.

    This might have restricted the front of my bobbins to 'rotate' as I had designed them to.

    I then machined the front section of the head 14mm whilst retaining the rear at its stock 16mm to act as a retaining 'flange' for the rotating front section of my bobbins.

    Everything was then chamfered and polished......the resulting 'reduced' heads enabling the 'inner' brass 'sleeve' of the front section of the bobbins to be visible whilst still having a retaining flange to keep the two part bobbins together...simple yet effective...



















    Sent from my SM-J320FN using Tapatalk
    Last edited by BG Wells; 09-08-2017 at 06:16 PM.

  23. #23
    BadAss Hooligan
    Join Date
    Mar 2009
    Location
    Nova Scotia, CANADA
    I just drooled on my screen....wow that's awesome work indeed.

    Sent from my SM-G930W8 using Tapatalk
    1999 green ZRX 1100

  24. #24
    BadAss Hooligan
    Join Date
    Jun 2016
    Location
    US
    Very nice. My plastic sleeved ones are getting chewed- up from using my stand

    Sent from my VS425PP using Tapatalk
    .
    .
    .
    .
    .
    .

    current bike: 2000 ZRX1100

  25. #25
    BadAss Hooligan
    Join Date
    Aug 2004
    Location
    San Jose, CA

    Re: Custom Japanese swingarm bobbins...

    Damn!! I don't even have a bike anymore and I'm tempted!

  26. #26
    Do you feel BRUCE!, punk?
    Join Date
    May 2007
    Location
    San Francisco Bay Area

    Re: Custom Japanese swingarm bobbins...

    Amazing workmanship Brian, especially in the incredible manual process of laying down the letters.
    2003 Green ZRX
    1983 Red Honda 1100F (sold)
    1983 Blue Honda 1100F (sold)
    1979 Honda CB650 Custom (broke cam/sold)
    1974 Honda CB450 (sold)
    1974 Honda CB450 (bad cam/stolen/sold)

  27. #27
    RIP 4/11/19
    Join Date
    Dec 2013
    Location
    The Netherlands

    Re: Custom Japanese swingarm bobbins...

    Unbelievable work, Brian!!!
    ███████ everything ████ ████ ██ is █ ██████ ██ fine ██████ █████ ███. ██████'█ ██ ████████. The ████ ███ █ government █████ ████ ██ knows ████ ████ best █ █████ ██.

  28. #28
    BadAss Hooligan
    Join Date
    May 2012
    Location
    West Blocton, Alabama

    Re: Custom Japanese swingarm bobbins...

    Wow! Are you a machinist for Rolex ?

  29. #29
    Hooligan
    Join Date
    Jun 2016
    Location
    Niagara Falls Canada

    Re: Custom Japanese swingarm bobbins...

    I have no idea how I’ve missed this topic but man oh man are you talented Brian. Very cool!!


    Sent from my iPhone using Tapatalk


 

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