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

    Custom machined Titanium rear wheel axle

    Following on from my recent thread regarding a custom Hybrid swingarm pivot http://www.zrxoa.org/forums/showthre...wing-arm-pivot I thought I'd follow in similar fashion by machining a custom rear wheel axle (spindle)

    This time though instead of converting a readily available part I chose to machine the rear axle from a length of 20mm grade 5 Titanium bar...

    Here it is alongside the stock OEM Kawasaki steel rear wheel axle...
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    Although it is assumed the stock rear axle is 20mm diameter it is in fact 19.94mm
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    And although you can purchase "20mm" Titanium bar is is never going to be exactly that....,and prior to purchasing I had the metal supplier confirm that my Titanium bar would be marginally larger than 20mm prior to purchase.....

    It arrived 20.10mm diameter....
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    Prior to machining a little preliminary inspection revealed the RHS eccentric had a recess machined in it that was not present on the LHS....

    As a result my custom Titanium axle would have to incorporate a collar as per the swing arm pivot... (albeit on the opposite end...)
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    So armed with a ball park length of 375mm (which would include a little "extra" either end to be trimmed off later) I set about preparing the Titanium for machining...
    So the first thing required was to "center drill" each end so a "live center" could support the bar at the 'Tail stock'
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    There is adequate length "between the centers" on my lathe to machine this in one single pass....however due to the length (even with solid 20mm titanium bar) you will get a little "whip" in the middle (the bar will oscillate during turning )

    Of course you could use a "Travelling Steady" to elevate that...,but I never liked them as they tend to get the in the way and crowd your access at both the head and tailstocks....

    Instead I opted to machine it in a single pass from either end (slightly past halfway and overlapping the middle...)....I find the bar much more rigid over the shorter length .......however you have to calibrate your tailstock to be 100% accurate with a dial..or you will run into a little innacuracy in the middle....
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    Ok so the bar set up to be machined from either end a little past halfway....(note the compound slide at a slight angle to clear the body of the tail stock...)
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    Plenty of lubricant and a slow speed for the pass when machining grade 5 Titanium (oh and make sure you use at least a tungsten bit...and it is sharp and the correct angle....:stpoke😊
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    One half done....look at the finish. (this is what you require and with so little to machine off you only get one go at it..!)
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    As determined by the diameter of the recesses in the eccentrics and the retaining circlips I was going to use my choice for the retaining nuts was to be Probolt Flanged M18 x 1.5 Titanium....https://www.pro-bolt.com/titanium-ax...-1-50mm-9.html

    These had a socket size of 24mm (and that would allow the outer diameter of a 24mm ×3/8" drive socket to fit inside the recess of the eccentric and also the inside diameter of a 34mm circlip to be compressed enough to allow it to fit...

    These nuts also had a flange diameter of 31.9mm so they worked perfectly with the eccentric recess and retaining circlip......in addition they had an overall height of 18mm so that determined how much I would need to machine thread either end of my axle...(albeit the RHS end would require more than the LHS on account of the required collar...
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    Ok so the machine bar is test fitted in the bike (prior to threading) to ensure all is well....
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    Happy so far...time to set up for running the M18 x 1.5mm threads ....and the Stock gearing needs changed as per the chart...
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    Stock gearing...
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    Removed....(it would be GREAT if I had a quick change gearbox....)
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    Gearing for 1.5mm metric threads fitted...
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    Speed selected....
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    Cross slide "zeroed" and the 'compound slide' set a 29.5°.....60° threading tool in quick change tool post aligned perfectly at 90°to the work and the threads ran....
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    Running M18 x1.5 mm 60°metric threads in 20mm grade 5 solid Titanium bar is quite hard on the tooling.....however with experience and a good technique here are the results....
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    Ok so a collar is required for the RHS.....and for this (as per the swingarm pivot) I chose aluminium billet....and ran an M18 x 1.5 internal thread...
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    As with the swing arm pivot it is recessed at one end to take me up to the 'datum line' I had marked on the RHS.....
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    The pre machined collar is threaded onto the RHS of the titanium axle to ensure its inner face arrives perfectly at the 'datum line)....note I used mole grips to do this at the end that has yet to be machined ....(so don't worry about that end being a little 'chewed' for this process.....).this was intentional.
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    Happy with that...I took some measurements so the collar could be finish machined....
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    The diameter of the flange is 32.5mm and its thickness 3.3mm....
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    The collar and nut are now screwed onto the titanium axle and the excess threads machined off...
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    A 32.5mm x 2.55mm washer for the LHS was machined.... (the recess in that eccentric is slightly 'shallower' than the RHS...hence the difference in the 'washer thickness' left versus right..)
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    Prior to fitting the collar both ends were 10mm 'gun drilled' to a depth of 30mm and machine finished.... (I did not want to go any deeper to impede on the 'load bearing' portions of the axle while still within the eccentric....
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    I sourced 34mm Stainless steel circlips for the recesses within the eccentrics to retain the flanged nuts from backing out...
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    Even though these were close...they still had to be 'modified' on both their inside and outside diameters to allow closure over the socket size 24mm nuts and still pass through the eccentric opening .....the modified clip alongside the Stock one... (modified on the RHS....)
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    And again ....(the pair of modified on the RHS...)
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    Ok so here are all the components for the Axle laid out...
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    Now for assembly...a little copper grease as a barrier and the collar is screwed on the RHS of the axle upmto the 'Datum line'....
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    Red threadlock applied and the RHS nut screwed on tightly...(during operation I DO NOT want the RHS nut unscrewing preventing me from getting the axle out so this nut has to go on .....PERMANENTLY...!!!
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    The remainder of the parts alongside. ...
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    The completed Titanium axle from either end....
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    Alongside the Stock OEM Kawasaki steel axle....
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    Ok so we looks good...but what does she weigh compared to the Stock one..?
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    867 g versus 538 g....function as well as form....

    A lot of work in this baby....however I'm very pleased with the result............but it is a One Off...! (no wonder Paul Kondraki got out of this business..!!!..)

    Stay tuned for the fitment of this over on my build thread....http://www.zrxoa.org/forums/showthre...ittle-makeover.

    Brian.
    Last edited by AV80R; 01-29-2018 at 10:01 PM.
    "A change in behaviour begins when Jesus changes our heart "

    Carina Wells (Mum)
    RIP.

    April 2017 BOTM~2017 BOTY
    #10080

  2. #2
    Just call me Gordon
    Join Date
    Aug 2015
    Location
    Springbranch TEXAS

    Re: Custom machined Titanium rear wheel axle

    Just WOW and .

    NOV 2017 BOTM
    #9927

  3. #3
    President of the ZRXOA
    Join Date
    Mar 2012
    Location
    Pleasanton, CA

    Custom machined Titanium rear wheel axle

    Very cool. This is the last axle I have to titaniumize! (I know, that’s not a word).
    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

  4. #4
    The Mod Father
    Join Date
    Apr 2016
    Location
    Lisburn.,Northern Ireland

    Re: Custom machined Titanium rear wheel axle

    Just noticed .... (predictive text...)

    The compound slide on the lathe should be set at 29.5° (not 20.5° as stated in the text which won't let me edit....)

  5. #5
    President of the ZRXOA
    Join Date
    Mar 2012
    Location
    Pleasanton, CA

    Custom machined Titanium rear wheel axle

    Quote Originally Posted by BG Wells View Post
    Just noticed .... (predictive text...)

    The compound slide on the lathe should be set at 29.5° (not 20.5° as stated in the text which won't let me edit....)
    Fixed it for you.
    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

  6. #6
    The Mod Father
    Join Date
    Apr 2016
    Location
    Lisburn.,Northern Ireland

    Re: Custom machined Titanium rear wheel axle

    Quote Originally Posted by AV80R View Post
    Fixed it for you.
    Many thanks Arash....,I appreciate that as I didn't want the information to be innacurate....

    I know and am well aware that you can thread cut using the cross slide only and have the thread cut on "both sides" of the tool......however Titanium (and stainless steel) are different.....and best cut on one side of the threading tool....via the compound slide at 29.5 Deg (Zero'ising the cross slide dial after each pass)

    Here is a superb video which explains the technique perfectly and in a much better way than I ever could..., without unnecessary jargon....(you advance the threading tool into the work via the 'compound slide' rather than the 'cross slide' as per threading aluminium ..,brass etc..)https://m.youtube.com/watch?v=Lb_BURLuI70

    Oh and his humour and approach is right up my street.!!

    Thanks again for your support and attention...
    Brian.
    Last edited by BG Wells; 01-30-2018 at 04:28 AM.

  7. #7
    RIP 4/11/19
    Join Date
    Dec 2013
    Location
    The Netherlands

    Re: Custom machined Titanium rear wheel axle

    Another fantastic job, Brian.
    Where will this end???
    ███████ everything ████ ████ ██ is █ ██████ ██ fine ██████ █████ ███. ██████'█ ██ ████████. The ████ ███ █ government █████ ████ ██ knows ████ ████ best █ █████ ██.

  8. #8
    BadAss Hooligan
    Join Date
    Feb 2017
    Location
    near Hamburg, Germany

    Re: Custom machined Titanium rear wheel axle

    Un - be - lie - va - ble!

    Compared to that, me in a shop is like an ape playing with clay.
    Godspeed Jaco. You're missed down here mate.

    Member number # 10085 ----------- BOTM July 2018 ----------- Restoring the old Gipsy

  9. #9
    BadAss Hooligan
    Join Date
    Mar 2005
    Location
    Lake Hartwell and I-85

    Re: Custom machined Titanium rear wheel axle

    Nice work, and great photo documentation.


    New Rules, Can't Say...

  10. #10
    Hooligan
    Join Date
    Mar 2018
    Location
    Lincolnshire

    Re: Custom machined Titanium rear wheel axle

    More amazing work

    Although I made one last week using nothing more than my trusty dremmel and some emry cloth......................................Ahem

  11. #11
    Bleeding Kawasaki since the 70's
    Join Date
    May 2002
    Location
    Charleston, TN -- bah-ha-wa-ha!

    Re: Custom machined Titanium rear wheel axle

    Brian, yer sick ... if'n I was Rich (or Arash) I'd try to merry ewe.

    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....

  12. #12
    The Mod Father
    Join Date
    Apr 2016
    Location
    Lisburn.,Northern Ireland

    Re: Custom machined Titanium rear wheel axle

    Quote Originally Posted by Mel View Post
    More amazing work

    Although I made one last week using nothing more than my trusty dremmel and some emry cloth......................................Ahem
    Hahaaa.........Group buy.??

    Thanks Mel for your kind comments.....
    Brian.
    "A change in behaviour begins when Jesus changes our heart "

    Carina Wells (Mum)
    RIP.

    April 2017 BOTM~2017 BOTY
    #10080

  13. #13
    The Mod Father
    Join Date
    Apr 2016
    Location
    Lisburn.,Northern Ireland

    Re: Custom machined Titanium rear wheel axle

    Quote Originally Posted by Perko View Post
    Brian, yer sick ... if'n I was Rich (or Arash) I'd try to merry ewe.

    SS
    .....it's not too often I'm propositioned (at my age..)

    Anyway here it is fitted ...check it out for more details here....http://www.zrxoa.org/forums/showthre...=1#post4813168

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    Brian.
    Last edited by BG Wells; 03-09-2019 at 11:55 AM.
    "A change in behaviour begins when Jesus changes our heart "

    Carina Wells (Mum)
    RIP.

    April 2017 BOTM~2017 BOTY
    #10080

  14. #14
    Hooligan
    Join Date
    Mar 2018
    Location
    Lincolnshire

    Re: Custom machined Titanium rear wheel axle

    New a lad who had an Aladins cave of old lathes, mills etc and had the tallent to produce almost anything ( popped in one day to find him machining a set of camshafts out of the Lancaster bomber for the memorial flight) Turned a pile of scrap aluminium (including an old fair ground ride) into a show wining trike, and when I say show winning, it cleaned up at all the largest shows around the UK, put a lot of custom shops noses out of joint.

    Looking forward to reading your build thread

  15. #15
    President of the ZRXOA
    Join Date
    Mar 2012
    Location
    Pleasanton, CA

    Re: Custom machined Titanium rear wheel axle

    :
    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

  16. #16
    Bleeding Kawasaki since the 70's
    Join Date
    May 2002
    Location
    Charleston, TN -- bah-ha-wa-ha!

    Re: Custom machined Titanium rear wheel axle

    I can't wait to see the Ti swingarm you mill!

    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....

  17. #17
    Hooligan
    Join Date
    Mar 2018
    Location
    Ireland

    Re: Custom machined Titanium rear wheel axle

    Spectacular results Brian.

    Are you a self-taught hobbyist or is/was this kind of thing your bread & butter?
    ZRXOA# 10078

    I got a bike for the wife.
    Best. Trade. Ever.

  18. #18
    2009 Hooligan of the year
    Join Date
    Sep 2001
    Location
    Austin, TX

    Re: Custom machined Titanium rear wheel axle

    I like that brake hanger. I may need to do something with mine.

    I tried chasing down a CF chain guard like that one, but it seems that exact type is no longer made. Is that actually the case? Or is there a dark corner of the internet I have failed to search?

  19. #19
    2009 Hooligan of the year
    Join Date
    Sep 2001
    Location
    Austin, TX

    Re: Custom machined Titanium rear wheel axle

    “Red threadlock applied and the RHS nut screwed on tightly...(during operation I DO NOT want the RHS nut unscrewing preventing me from getting the axle out so this nut has to go on .....PERMANENTLY...!!!”

    Why not drill it to install a pressed pin, or maybe a couple of set screws?

  20. #20
    The Mod Father
    Join Date
    Apr 2016
    Location
    Lisburn.,Northern Ireland

    Re: Custom machined Titanium rear wheel axle

    Yes the drilling and threading a 'grub screw' into the nut on the collar'ed end was and is a viable option Chris...

    I had considered doing this.......however as the objective was to remove the possibility of that particular nut from turning or backing out...,the red threadlock method was the option I decided upon.

    In addition it kept all the 'faces' of the titanium nut 'clean' (not having a pin or grub screw visible)

    Either method would have worked ......and each was indeed a consideration (for better or worse...)

    Brian.
    "A change in behaviour begins when Jesus changes our heart "

    Carina Wells (Mum)
    RIP.

    April 2017 BOTM~2017 BOTY
    #10080

  21. #21
    The Mod Father
    Join Date
    Apr 2016
    Location
    Lisburn.,Northern Ireland

    Re: Custom machined Titanium rear wheel axle

    Quote Originally Posted by zrx24 View Post
    I like that brake hanger. I may need to do something with mine.

    I tried chasing down a CF chain guard like that one, but it seems that exact type is no longer made. Is that actually the case? Or is there a dark corner of the internet I have failed to search?
    PM sent....
    "A change in behaviour begins when Jesus changes our heart "

    Carina Wells (Mum)
    RIP.

    April 2017 BOTM~2017 BOTY
    #10080

  22. #22
    RIP 4/11/19
    Join Date
    Dec 2013
    Location
    The Netherlands

    Re: Custom machined Titanium rear wheel axle

    I REALLY hope I get to see your bike one day, Brian! I will take hours just staring at all the details.
    ███████ everything ████ ████ ██ is █ ██████ ██ fine ██████ █████ ███. ██████'█ ██ ████████. The ████ ███ █ government █████ ████ ██ knows ████ ████ best █ █████ ██.

  23. #23
    The Mod Father
    Join Date
    Apr 2016
    Location
    Lisburn.,Northern Ireland

    Re: Custom machined Titanium rear wheel axle

    Quote Originally Posted by pedrosixfour View Post
    Spectacular results Brian.

    Are you a self-taught hobbyist or is/was this kind of thing your bread & butter?
    Thanks Damien.........I have a pretty chequered background..

    I was a Self employed joiner for 38 years ......and back in the late 1980 and 90's spent a number of years as a master pattern maker for a number of model company's making prototype models that would go into Production...

    For 5 consecutive years I took the Gold award at the word renowned "Euro Militaire" in Folkstone England for Scratch Built Armoured Fighting Vehicles. ...

    I was also for a number of years a feature writer and reviewer for three magazines British ...,American. ..and Japanese (Military Modelling ..,Fine scale Modeler...,and Model Graphix)



    Now I work as Primary School Caretaker..... (out to grass now...Lol.)
    "A change in behaviour begins when Jesus changes our heart "

    Carina Wells (Mum)
    RIP.

    April 2017 BOTM~2017 BOTY
    #10080

  24. #24
    Hooligan
    Join Date
    Mar 2018
    Location
    Ireland

    Re: Custom machined Titanium rear wheel axle

    Quote Originally Posted by BG Wells View Post
    Thanks Damien.........I have a pretty chequered background..

    I was a Self employed joiner for 38 years ......and back in the late 1980 and 90's spent a number of years as a master pattern maker for a number of model company's making prototype models that would go into Production...

    For 5 consecutive years I took the Gold award at the word renowned "Euro Militaire" in Folkstone England for Scratch Built Armoured Fighting Vehicles. ...

    I was also for a number of years a feature writer and reviewer for three magazines British ...,American. ..and Japanese (Military Modelling ..,Fine scale Modeler...,and Model Graphix)



    Now I work as Primary School Caretaker..... (out to grass now...Lol.)
    It must be the best-kept school in the country! And, judging by your "interests" could be a safe place to hold-up when the world does take a dump.

    I have access to a little single phase Rockford lathe in work, it was dropped into us for unknown reasons and it eventually found a little home in the corner beside a plug socket. It's a little loose (and I'm a little shit) for precision work, perhaps a service (training) might improve things, but it has certainly dug me out of a couple of holes and I'd be sad to see it go.

    If I won the lottery tomorrow work could kiss my ass, but I'd still have a nice workshop with a few key pieces of engineering and fabrication equipment.
    ZRXOA# 10078

    I got a bike for the wife.
    Best. Trade. Ever.

  25. #25
    Just call me Gordon
    Join Date
    Aug 2015
    Location
    Springbranch TEXAS

    Re: Custom machined Titanium rear wheel axle

    I could and have spent hours just looking at all the detail on Brian's evolving build and every time I look I find more that I've missed previously ! I think a ZRX calendar could be done just an individual components of this bike great job SIR

    NOV 2017 BOTM
    #9927

  26. #26
    BadAss Hooligan
    Join Date
    Feb 2017
    Location
    near Hamburg, Germany

    Re: Custom machined Titanium rear wheel axle

    Quote Originally Posted by Deerslayer64d View Post
    ... I think a daily ZRX calendar could be done just an individual components of this bike great job SIR
    Fixed it for you.
    Godspeed Jaco. You're missed down here mate.

    Member number # 10085 ----------- BOTM July 2018 ----------- Restoring the old Gipsy

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

    Re: Custom machined Titanium rear wheel axle

    Quote Originally Posted by Deerslayer64d View Post
    I could and have spent hours just looking at all the detail on Brian's evolving build and every time I look I find more that I've missed previously ! I think a ZRX calendar could be done just an individual components of this bike great job SIR
    That will just make us all feel incompetent...
    ███████ everything ████ ████ ██ is █ ██████ ██ fine ██████ █████ ███. ██████'█ ██ ████████. The ████ ███ █ government █████ ████ ██ knows ████ ████ best █ █████ ██.

  28. #28
    The Mod Father
    Join Date
    Apr 2016
    Location
    Lisburn.,Northern Ireland

    Re: Custom machined Titanium rear wheel axle

    Quote Originally Posted by jacohatt View Post
    That will just make us all feel incompetent...
    No worries you can buy underwear for that condition......
    "A change in behaviour begins when Jesus changes our heart "

    Carina Wells (Mum)
    RIP.

    April 2017 BOTM~2017 BOTY
    #10080

  29. #29
    RIP 4/11/19
    Join Date
    Dec 2013
    Location
    The Netherlands

    Re: Custom machined Titanium rear wheel axle

    Quote Originally Posted by BG Wells View Post
    No worries you can buy underwear for that condition......
    Did you just make a grandpaw joke?????
    ███████ everything ████ ████ ██ is █ ██████ ██ fine ██████ █████ ███. ██████'█ ██ ████████. The ████ ███ █ government █████ ████ ██ knows ████ ████ best █ █████ ██.

  30. #30
    The Mod Father
    Join Date
    Apr 2016
    Location
    Lisburn.,Northern Ireland

    Re: Custom machined Titanium rear wheel axle

    Quote Originally Posted by jacohatt View Post
    Did you just make a grandpaw joke?????
    Whaadya mean Joke.......I'm wearing them... (on the outside of my trousers now..)......Lol.
    "A change in behaviour begins when Jesus changes our heart "

    Carina Wells (Mum)
    RIP.

    April 2017 BOTM~2017 BOTY
    #10080


 

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