SolidWorks/CAM file generation & General Fabrication Request

StoopidEngineer

New Member
Good Morning All!

Just to give you a quick rundown of where I am: I’m new to this site, but I’ve been a big fan of the café style bikes since first seeing them start to pop up several years ago. This seems to be one of, if not the definitive source for the café community, and I’m very glad to have found it. I actually was searching for a cheap alternative to replace the leaking tank on one of my bikes, and by googling around, found a thread on making parts out of carbon fiber, that led me to a thread about making fiberglass parts here.

I turn 27 in a couple of days, and work full time as a Mechanical Engineer designing automation equipment. I’ve been a rider all my life, have had a pretty wide variety of street bikes (and more dirt bikes than I can remember) including a Honda 919 that I just sold to help cover the cost of adopting a little girl from Colombia with my wife. My wife in her infinite patience (and desire to have me out of her hair while she does her schoolwork) has allowed me to keep an 80 XS850G and an 86 XS600. As soon as I can get the headlight working and the carbs cleaned up on the triple, I’ll be using that for my commuter while I hack the little Radian to pieces to make something unique out of it.

Here comes the actual reason for the post: I use SolidWorks 2012 10 hours a day, every day, so my design/CAD skills are solid, but where I lack experience is fabrication. I’ve spent very little time actually cranking handles, and my welding skills are only suitable for anything that will never be seen by anyone but me. I don’t have a mill, bender, welder or anything fancy in the little garage that I work out of, as most of my money is tied up in the HUD home I’m rehabbing, and the ongoing adoption. BUT, I have a friend who is a tech teacher at a high school that has a couple of CNC mills, and gets all his stock as donations.

What I’m looking for help with (hopefully from someone else who is SolidWorks literate) is taking a SolidWorks file (or .stp or .igs, ect.) and writing the program to make it on one of his CNC mills. I remember reading an article in Machine Design a while back about CAM freeware, but can’t find that magazine now that I need it. If anyone has any guidance for me, I would greatly appreciate it. Also, if you guys have any other good information as far as learning the skills (I would love to pick up some work on the side making parts, but can’t find a shop that’s willing) to fabricate parts for a bike, I would greatly appreciate it.

One of the ideas for the Radian will be replacing the twin shock rear suspension and ugly aluminum swingarm with a monoshock and tubular steel swingarm (which I thought was a really original idea until I saw Confederate and Peregrine’s take on that.

So if you’ve actually gotten down this far in the post, undeterred by my ramblings, any advice or help you can offer on learning to make CAM files from solid models, and on fabrication in general would be greatly appreciated. Thanks Guys!
 
I only do CAD (Cardboard Aided Design) so I can't help at all on that stuff. On the fab end, it's much easier. Almost anything you can think of can be drawn with pen and paper and can be made with simple tools that have been around for decades.

Complex fully machined parts can't be, of course, but most fab doesn't need much of that. Swingarm conversions are a little more complex for a relative newb. Most of us find a suitable donor and modify it as little as possible to get it to fit and then work out spring and damping the old empirical way a.k.a. "suck it and see".

Unless you are committed to a long costly project, I'd suggest maybe look at th radian and think about it as a two stage process. Stage 1 - maximum change to looks and fuctionality but small change to running gear - for minimum bucks. Stage 2 next year perhaps, plan the more major changes to suspension etc.
 
Solid advice teazer! :)

I sent you a PM! Contact him! ;) 8)
 
Wow, I figured it'd be a while before I got any responses - very cool that this is such an active forum.

Thanks for the advice and the input guys!

And if anyone else is skilled/experienced with CNC programming (either based on solid models or just straight CNC programming) I'd still appreciate any input that you guys have for how to get started. I love to learn new stuff, which is what got me to this forum in the first place.
 
Re: The Radian-- I have an 86 that just went through a ground up resto. A couple of words to the wise: Check the frame before u invest a lot of time and effort.When Yammie put the Radian out it was basically a "what we got in the parts bin" project. Frame has weak points where tabs are welded so be sure it does not have hidden rust. Second, front forks are suspect so be prepared to rebuilt those suckers before any attempts to do a monoshock rear unless u want ur face all over some asphalt on hard braking. 3. I got lotso Radian parts so ask if u need something.Good luck.BJ
 
Thanks hocbj23 - I haven't even begun to get into the bike yet; I picked it up from a guy I worked with who was using it as a commuter, and then let it sit while I worked on my house for a year. It looks like the fork seals are weeping some oil, so I had planned on getting into them anyway. I knew the welds on the frame were ugly, but I would have never suspected any of them, so thanks for the heads up. My goal with the monoshock is actually to maintain the stock geometry as much as possible, and design it around a budget shock.

And hats off to you for doing a resto on a Rad, if mine were in better shape overall and had less miles on it, I would probably consider just taking it back to stock. As it is, I'm just going to have as much fun with it is as possible.
 
Kewl on ya.Keep us posted.My Rad cam out of a storage unit where it had reposed for about 10 years.Dirty,greasy and some lame had rattle canned most of it flat black--BUT I put some fuel in it and a new battery and the damn thing started.Talk about surprised.Lol.So now it has a powdercoated frame,Mazda Z1 teal paint on the tank,tins and fender, ceramic coated Kerker 4-1 from a FZ,oil cooler from same bike,Hagon shocks,rebuilt forks with emulators,a fairing from an old Zuki 750,new chain and sprockets ,FZ cams, motox bars and a new seat.Bike runs and handles great and is schweet to look at so Im very pleased with how it came out.Plus u never meet urself out riding.luck with urs.Another tip-when I started checking the fuse box and wiring attached to it, the fuse box basically fell apart in my hands.Invest a few bucks and wire in an aftermarket blade type box--u will be glad u did.bj
 
I've got an 86' Radian I'm starting to "restore" for my wife. I'd love to see your pics (StoopidEngineer, hocbj23, etc..)
 
cc:Glad to but I am a tech moron.Have lots of pics of the Rad laying around so if u will PM me an addy I will send u all u want.BJ
 
For your tube swingarm, one of the place's i do welding at and they prefer to work off solidworks files. http://www.cartesiantube.com/index.html
Tell them you were referred by Kevin

You must provide your own dimensions. These guys aren't bike guys and will not be able to help you with suspension locations or any other bike related queries. They will ONLY be able to help with tubing related queries such as diameter, wall thickness, material vs strength, bend capabilities...........
And again, Solidworks is the preferred files. Now with that in mind, they can provide precision notched and bent tubes from rear loops to complete bike frames.
 
reds - thanks for the info man; I'll probably send them a rough part model for a quote just to see what they come back at.

hocbj23 - Do you happen to have a front brake master cylinder/lever assembly? My Radian's is missing, and I haven't had much luck finding an affordable replacement yet.

Also - anyone have any good leads for motorcycle junkyards in upstate NY? I'm in the Rochester area.
 
Hello I'm a Mechanical engineering student and in high school we used a product that was called Camworks that was installed within solidworks. Check out there web site they are beta testing their 2013 product line and you might be able to get some free use out of it. As for the actual use of camworks it was pretty straight forward but it was all set up for me by my teacher.
http://www.camworks.com/
 
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