View Full Version : CNC Project
As some of you may have seen, Graham Wilhelm (Wilhelm on OTN) did a little CNC project in which he integrated the top maggie mount and the brake booster. As seen HERE (http://www.observedtrials.net/vb/showthread.php?t=25333&highlight=bored), and HERE (http://www.observedtrials.net/vb/showthread.php?t=25619&highlight=bored).
I talked with Graham about the project and ended up designing my own. The part was designed in Pro/Engineer and the CNC instructions were created with Pro/Manufacturing. The entire mfg process took less than 3 hours, ~2 hours to create the file and ~1 hour to mill out the part. Here are some pictures of the part and mfg process.
Pro/E Render
http://students.ou.edu/M/Ross.A.Morgan-1/gallery/booster/render.jpg
CNC Mill Tool Changer
http://students.ou.edu/M/Ross.A.Morgan-1/gallery/booster/DSC02562.jpg
Work Piece
http://students.ou.edu/M/Ross.A.Morgan-1/gallery/booster/DSC02563.jpg
Backside Milling
http://students.ou.edu/M/Ross.A.Morgan-1/gallery/booster/DSC02567.jpg
Backside Milling Complete
http://students.ou.edu/M/Ross.A.Morgan-1/gallery/booster/DSC02568.jpg
Completed
http://students.ou.edu/M/Ross.A.Morgan-1/gallery/booster/DSC02570.jpg
http://students.ou.edu/M/Ross.A.Morgan-1/gallery/booster/DSC02571.jpg
http://students.ou.edu/M/Ross.A.Morgan-1/gallery/booster/DSC02573.jpg
http://students.ou.edu/M/Ross.A.Morgan-1/gallery/booster/DSC02574.jpg
http://students.ou.edu/M/Ross.A.Morgan-1/gallery/booster/DSC02575.jpg
http://students.ou.edu/M/Ross.A.Morgan-1/gallery/booster/DSC02578.jpg
Let me know what you think...
esfrost
01-19-2007, 12:07 PM
How stiff is it compared to the old booster on the gorund?
Kibble Fat
01-19-2007, 12:08 PM
That Looks amazing :eek5:
Ross W.
01-19-2007, 12:12 PM
pretty sweet, nice work.
How's it feel?
I am sure my opinion is biased b/c I took alot of time making the part, but I think I can notice a significant difference in the feel of the lever, and I can visually see less deflection of the booster/bolts as compared with my previous setup (ECHO booster).
lucky13
01-19-2007, 12:20 PM
How much you want for another one?
Seriously. But I like my stuff annodized black.
Patrick
01-19-2007, 12:44 PM
pretty cool. Looks burly
mcdub
01-19-2007, 01:18 PM
Looks fucking tank proof
I will admit, the thickness of the piece is probably a bit overkill, but it still only weighs ~200 grams.
toyota200x
01-19-2007, 01:32 PM
The arch looks crazy thick. Wow, nice work.
darkside
01-19-2007, 02:17 PM
Impressive!
mcdub
01-19-2007, 02:17 PM
200 GRAMS!!!!
The last booster I owned was like 25g to 50 max.
But I broke it on a rock :rant2:
jamesb
01-19-2007, 02:28 PM
Looks like a neat idea. Only issue I can see is that the cross-over might be pushed down a lot more weakening it? It depends on your seat stay angle compared to the rim I guess.
mcdub
01-19-2007, 02:31 PM
Hoses are made to bend.It will be fine.
ChrisB
01-19-2007, 02:47 PM
cool idea
Mango
01-19-2007, 04:03 PM
good stuff i like it when riders come out with cool setups that could be manufactured by a company.
SpeedyS
01-19-2007, 07:45 PM
There goes the bolt flex issue, nice work!
Trialsaddict
01-19-2007, 10:27 PM
Really nice work, Ross!
Looks good, and I'm sure with a little time, you'll fine tune it etc. I'll look forward to checking it out sometime soon. Keep us posted.
stefan
01-20-2007, 05:51 AM
holy cow !
what a fine idea of design ! should have been made long time ago by big compagnies ! and you did it !
only thing is the weight...
MegamoMidwest
01-20-2007, 06:01 AM
it looks surprisingly clean for how thick it is - good job.
-Paul
It weighs 163 grams. I dont think that is much heavier than a standard booster/ magura mount/ long bolts and spacer setup.
Alex_M
01-20-2007, 12:04 PM
It weighs 163 grams. I dont think that is much heavier than a standard booster/ magura mount/ long bolts and spacer setup.
NICE! yea the weight is good i guess! :naughty: Seriously good job!
lucky13
01-20-2007, 01:15 PM
seriously,.. are you making another?
MIKE1968
01-20-2007, 01:31 PM
The only reason I have a booster is to keep my ankle from kicking the bottom of the crossover on either side, this this doesn't do that.
Good idea though, sure lots like it.
lucky13
01-20-2007, 06:46 PM
So a booster "with wings" is what you need?
I need that sort of bumper protection as well. Missed sidehops and bails always whack my hose ends by the cylinders.
HA-Ha,...... whack.
carnagr
01-20-2007, 06:56 PM
How about for stiffness?
lucky13
01-20-2007, 07:11 PM
For stiffness use my epic wang.
lucky13
01-20-2007, 07:12 PM
+10 damage
CoppellStereo
01-21-2007, 04:04 AM
that is soo awesome
dkoppric
01-22-2007, 08:44 AM
wow, great idea. never seen a booster integrated with hs-33 mounts before.
But why didn't you make this piece the lower piece of the clamp and by this it could have been lower on the frame!?!
wow, great idea. never seen a booster integrated with hs-33 mounts before.
I wish I could take credit for the idea...as I stated in those links at the top, graham wilhelm came up with the idea and also made something like this. I merely came up with my own design on his idea. Thanks for all the comments, guys.
The reason it is a better idea to have the this as the top mount and not the bottom, is b/c if it were at the bottom the bolts would deflect more since there is no force "holding" them together when the brake is applied.
gtrials
02-03-2008, 11:34 PM
Yeah, ross, great job. Are you an engineering major?
RyanMcVicker
02-04-2008, 12:13 AM
i thought all frames nowadays had built in boosters in the seatstays..
nice work tho looks pretty stiff.. just heavy
Bryan
02-04-2008, 12:30 AM
i thought all frames nowadays had built in boosters in the seatstays..
nice work tho looks pretty stiff.. just heavy
They don't, and built-in boosters don't work as well anyways.
But I agree that it could lose a little weight
dready_dan
02-04-2008, 12:30 AM
nice job ross. next time machine your name in it: OKIE BIG PIMPIN
ha ha. see ya soon.
RyanMcVicker
02-04-2008, 12:33 AM
you dont need a booster if you have one built in its already added weight..
TTownJon
02-04-2008, 12:42 AM
not necesarily true. Even if you have a built in booster, you still have the flex in the bolts.
RyanMcVicker
02-04-2008, 10:40 AM
not that it makes a huge difference... all the world champs dont ride boosters just cause they have 1mm of flex...they just ride the shit :greddy:
[BMF] Chris
02-04-2008, 01:46 PM
how will this device improve my rear disc brake.........
CordyBoy
02-04-2008, 02:47 PM
That looks very good. The design is well smart. Are you going to start selling them? I'd buy one.
rndm*dv8n
02-04-2008, 05:01 PM
It's one of those things where, when you look at it, you think: "it's about time". Now we just need an ISO width for maggie mounts.
Dang!
02-04-2008, 05:25 PM
I wish I could take credit for the idea...as I stated in those links at the top, graham wilhelm came up with the idea and also made something like this. I merely came up with my own design on his idea. Thanks for all the comments, guys.
The reason it is a better idea to have the this as the top mount and not the bottom, is b/c if it were at the bottom the bolts would deflect more since there is no force "holding" them together when the brake is applied.
I'm glad you gave Graham props, It's a brilliant idea he came up with.
I've thought about making a version as well, but came to across an design issue that has held me back.
It is frame specific booster, as the four bolt mount on one frame to the next is slightly different. IE: the slot in all brake boosters, which accommodates for this.
So if you can develop an eccentric mount that doesn't drive the cost or weight over the line, you'll really have something.
Other than that, it looks great.
Mad props for doing your own thing, keep it up!
stocktrials
02-04-2008, 06:04 PM
related to the HEN bikes similar thing?
good ideas
TTownJon
02-04-2008, 06:26 PM
not that it makes a huge difference... all the world champs dont ride boosters just cause they have 1mm of flex...they just ride the shit :greddy:
just saying, it does serve some purpose. Plenty of people like the feel of having no flex in their rear brake.
RyanMcVicker
02-04-2008, 10:05 PM
fact.
WhiteRavenKS
02-04-2008, 10:05 PM
you dont need a booster if you have one built in its already added weight..
you dont need a rear brake if you ride everything perfectly. might as well take that off too since it's just extra weight.
Bryan
02-05-2008, 02:25 AM
tra has proven we don't need a front tire, either. 8kg bike here I come
Bryan
02-05-2008, 02:26 AM
I'm glad you gave Graham props, It's a brilliant idea he came up with.
I've thought about making a version as well, but came to across an design issue that has held me back.
It is frame specific booster, as the four bolt mount on one frame to the next is slightly different. IE: the slot in all brake boosters, which accommodates for this.
So if you can develop an eccentric mount that doesn't drive the cost or weight over the line, you'll really have something.
Other than that, it looks great.
Mad props for doing your own thing, keep it up!
maybe there should be a standard maggie mount distance? 100mm?
Mat_P
02-05-2008, 02:41 AM
nice work :)
kimosabi-> please read this thread...your ideas are fucking shithouse, take notes, learn, make something worthwhile. :momaru:
Dang!
02-05-2008, 05:36 AM
maybe there should be a standard maggie mount distance? 100mm?
No doubt- 100mm is what boosters are based on, but as rims get wider and wider, the available room for a fresh set of pads gets smaller and smaller.
Peter Green
02-07-2008, 04:11 PM
http://trialshop.ru/shop/komplektujushhie_k_tormozam/bustery__kreplenija/hen_monobuster/
heres a good one
Dang!
02-08-2008, 06:23 AM
http://trialshop.ru/shop/komplektujushhie_k_tormozam/bustery__kreplenija/hen_monobuster/
heres a good one
The Hen booster looks pretty cool, but I still don't see how it's adjustable? Maybe your supposed to stretch it?
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