Author Topic: CB550 or CB500 Aluminum Side Cover Castings (build?) (Read 13330 times)

wolf550 · « **Reply #125 on:** February 05, 2023, 04:25:04 PM »

took a little cutting and drilling to get those fins out but the emblem went in good.

wolf550 · « **Reply #126 on:** February 05, 2023, 04:27:31 PM »

went on to fill in with clay on the areas where the sand would just get stuck and break off.
getting ready tomorrow to make the first batch

wolf550 · « **Reply #127 on:** February 05, 2023, 04:33:13 PM »

Im sorry to say that this will have to be what the new standard will be.
I haven't had any traffic on the points covers in the for sale section so I will most likely take them down and keep for nostalgia.
I will have to get those others moving right along.
we will see.

wolf550 · « **Reply #128 on:** February 06, 2023, 05:21:49 PM »

kept on having trouble with the molds and weather being cold but today seemed good so went ahead and cast one up.
you can really see the difference on how that missing fin brings it together.

wolf550 · « **Reply #129 on:** February 09, 2023, 05:22:56 PM »

Had some time today so finished grinding off the excess aluminum, holes drilled sanded and fitted.
not sure if I want to sand down the fins and emblem like the other.

wolf550 · « **Reply #130 on:** February 10, 2023, 06:16:20 PM »

so I got home and started work on the second finned cover I cast with the fin intact.
after some work deburring, sanding and dremel the areas around the emblem I started to like how it looks alot better than the cover that hasnt beenworked on yet.
what do you guys think?

CycleRanger · « **Reply #131 on:** February 10, 2023, 10:02:28 PM »

Better and better!

wolf550 · « **Reply #132 on:** February 11, 2023, 02:59:05 PM »

thanks cycleranger!
I decided to go all the way with the other cover and sand down all the casting blemishes and what not.
I think it looks clean and ready to go.

Gurp · « **Reply #133 on:** February 11, 2023, 05:24:36 PM »

Sharppp

Now time to expand to other popular models. Idk if you seen what these type covers sell for on HD stuff and XS650s. It's a nice market if you make a quality product. Oh boy, you got that part down!

grcamna2 · « **Reply #134 on:** February 11, 2023, 08:45:29 PM »

Quote from: CycleRanger on February 10, 2023, 10:02:28 PM

Better and better!

+1

I can imagine how much work it is to cast one and then file & sand it all smooth

wolf550 · « **Reply #135 on:** February 11, 2023, 09:13:21 PM »

Quote from: Gurp on February 11, 2023, 05:24:36 PM

Sharppp

Now time to expand to other popular models. Idk if you seen what these type covers sell for on HD stuff and XS650s. It's a nice market if you make a quality product. Oh boy, you got that part down!

thanks Gurp! I went downstairs to the shop ((garage) not even big enough to fit a car) around 9 before I knew it the wife was bangin on the floor for me to come up for dinner!
It will be nice to get this side hustle going as a true small business to branch out and expand on other brands. I would have to talk to someone about copyright issues if any to reproduce these on a larger basis. It looks like I just have to get it started.

wolf550 · « **Reply #136 on:** February 11, 2023, 09:19:14 PM »

Quote from: grcamna2 on February 11, 2023, 08:45:29 PM

Quote from: CycleRanger on February 10, 2023, 10:02:28 PM
Better and better!

+1
I can imagine how much work it is to cast one and then file & sand it all smooth

When I first started, a couple of weeks would be sqeezing it for a finished piece, but a weekend now seems to be a good enough time.
all that sanding by hand take a long time. it would be better with a machine and a shop in the future for this.
gotta get a business plan together so I can quit the 9 to 5 and work this out moving forward.

grcamna2 · « **Reply #137 on:** February 11, 2023, 09:39:35 PM »

Do you spray the sand after it's been formed?
I was curious if they have a type of spray that can best keep the sand in it's formed shape while you're allowing the liquid aluminum to run into and fill-up the mold ?

wolf550 · « **Reply #138 on:** February 11, 2023, 10:21:14 PM »

the green sand I use, something in the materials keep the clay and sand to fuse when it starts to dry out making it like a pottery.
right now the green sand is a low detail grit sand.
there are other levels that are a high detail grit that will show your finger print in high definition detail but more expesnive.
it would give the best detail for 3d printed covers that dont have flaws or imperfections like on my molds.
when I make a mould and release the cover from the greensand I don't mate the two halves immediately I expose it heat to get it dry on the surface and then leave it overnight to cure i guess into the pottery phase of it.
if I don't and try to pour a casting the moisture that is in the greensand will cool the aluminum too fast and cause problems like not filling and causing distortions on the face.
I have a 750 cover that ill have to take a pic of it.
there is a guy I check out on youtube (wowthings) where he sprayed fuel on the mold and lights it on fire to harden quickly but he is using a oil based clay sand.

grcamna2 · « **Reply #139 on:** February 11, 2023, 11:15:31 PM »

Quote from: wolf550 on February 11, 2023, 10:21:14 PM

the green sand I use, something in the materials keep the clay and sand to fuse when it starts to dry out making it like a pottery.
right now the green sand is a low detail grit sand.
there are other levels that are a high detail grit that will show your finger print in high definition detail but more expesnive.
it would give the best detail for 3d printed covers that dont have flaws or imperfections like on my molds.
when I make a mould and release the cover from the greensand I don't mate the two halves immediately I expose it heat to get it dry on the surface and then leave it overnight to cure i guess into the pottery phase of it.
if I don't and try to pour a casting the moisture that is in the greensand will cool the aluminum too fast and cause problems like not filling and causing distortions on the face.
I have a 750 cover that ill have to take a pic of it.
there is a guy I check out on youtube (wowthings) where he sprayed fuel on the mold and lights it on fire to harden quickly but he is using a oil based clay sand.

I like understanding it,thanks.

newday777 · « **Reply #140 on:** February 12, 2023, 01:51:51 AM »

Quote from: wolf550 on February 11, 2023, 02:59:05 PM

thanks cycleranger!
I decided to go all the way with the other cover and sand down all the casting blemishes and what not.
I think it looks clean and ready to go.

Nice!

RAFster122s · « **Reply #141 on:** February 12, 2023, 04:16:13 AM »

Look up plans for belt sanders, guys will make them out of wood and run sanding belts... Even thickness planers can be made from wood belt sanding setups...

Just a thought for fabbing a tool to finish the cast aluminum pieces.
A drill press would be needed for drilling the holes and facing the bolt head areas.

wolf550 · « **Reply #142 on:** February 12, 2023, 06:33:16 AM »

thanks rafster I have no knowledge of the tools that are out there already made for this kind of defining work to be done.
I just get to a bump in the process that my head says "I need to do this to it. what do I have that can do this"
if that draws out nothing I have I check out some vids on youtube of what other people are doing to get it done.
Ill have to eventually seek out a proper business for this kind of stuff to see what the best options are for this to get into the game.

wolf550 · « **Reply #143 on:** February 12, 2023, 12:05:54 PM »

a few pics of my haste not waiting to let it dry out all the way on the surface

wolf550 · « **Reply #144 on:** May 14, 2024, 05:20:31 PM »

I am reviving this thread for the last side cover that I was working on but never got off the ground the finned 500/550 cover. Gurp asked me for one and decided this will be the first and last one I will make. started with a few different ways to see if I could mould the cover and use one of my finned covers to press in the sand but it was not working. also the box was not tall enough. it was missing about 2 inches so I may a new box top to allow for more sand. after many unsuccessful attemps Ive decided to do it the hard way and make the side cover with extra aluminum on the outside and remove the aluminum with my bastard rasp.

wolf550 · « **Reply #145 on:** May 14, 2024, 05:21:56 PM »

with the amount of material i am adding it will take some time by hand but should look good.

wolf550 · « **Reply #146 on:** May 14, 2024, 05:23:16 PM »

the fins will be about a half inch but will round them out to follow the curve of the cover

wolf550 · « **Reply #147 on:** May 14, 2024, 05:24:48 PM »

If I had a cnc machine it would be easier to just mill out the fins but what fun would that be

wolf550 · « **Reply #148 on:** May 17, 2024, 11:59:40 AM »

casting came out good. going to cut and sand down and see about a test fit.

Gurp · « **Reply #149 on:** May 18, 2024, 05:02:59 PM »

Cover is looking killer.
a manual mill would even be a huge help with that.

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Author Topic: CB550 or CB500 Aluminum Side Cover Castings (build?) (Read 13330 times)