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Discussion Starter · #1 · (Edited)
I wanted to take a moment and extend a big Thanks to Jay at Tsunami for his help yesterday. He was very, very helpful and polite as he educated me on the proper setup of the clutch and getting the right parts.

Very pleasant to deal with and highly knowledgeable. Pretty cool.

The Phantom, while in near perfect condition, had a few minor issues. Mostly surrounding the clutch.

Finding the appropriate parts for a bike like this takes a bit of work. Jay was great at getting me all the stuff I wanted/needed.

Ordered an entire new BZM clutch assembly along with 80, 79, and 78 mm bells. Springs, shoes, hardware, all sorts of goodies.

Then came the work. The bearing on the clutch cover was nuked. It'd seen its share of heat and funk from clutch dust. As I'm removing it in the press I notice that one ear of the cover is flexing more than the others. The bugger had a crack. I played with it and it fell right off.

This is a part only available from Italy so what to do?

MAKE YOUR OWN!

I measured everything and whipped up two drawings in MasterCam X3. Wrote my tool paths, set up a piece of 7075 AL and went to making some chips.

I think the OEM part was first turned in a lathe to create the radius on the outside finish. I could have done that on my CNC turning center but it would of required a lot of setup work as I typically use only collets in my machine. Changing to a chuck is about a 2 hour process and it sucks doing it.

I generated a revolved solid model, converted it to a surface, and used a scalloped surfacing tool path instead.

Here's the original part and the one I made:





As you can see I added a little meat to mine to aid in the long term durability. The OEM part was pretty thin right at the transition from the legs to the bolt boss. I increased the thickness of the material here another .05" to strengthen it by creating a domed radius on the top of each leg. . I also widened the 4 legs to give it some additional strength where it ties into the center bearing support.

I don't have an M5x.8mm tap so I'll make a trip this am to a tooling vendor so that I can finish this up. Going to replace the mounting bolts also just so everything is ship shape.

Fun stuff!



 

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Discussion Starter · #2 ·
Next project is sprockets!

I crunched the numbers on the #25 chain and drew up a 65T sprocket for it last night. Then did a 66T, 67T, 68T, and 69T as well. Going to pick up some 1/4" 6061T6 AL plate today so I can get them whipped up over the weekend.

I'll probably make some for the Blata as well.

Later!

C
 

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Nice Work, looks real strong, and it looks good too, that's a good combo,lol. I like you already,lol.
 

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French Fries N Cheese
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Glad to know you're finding all the parts you need... Yeah tsunami are very good at customer service, and almost always have that one part you really need. No ordering parts that dont fit, they make sure they are selling you what you need.

Nice work on the bell housing, nice, clean and sturdy.
 

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I live in Northern California, and it was the only decent place I could find a C1 China bike. $510 to my door, but that was a couple of years ago.
They told me put Dupont Viton head O rings in it, but I did not listen and the engine filled up with water a few weeks later. You have to call and ask for them, there not on the website.
They know there stuff.
 

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I wanted to take a moment and extend a big Thanks to Jay at Tsunami for his help yesterday. He was very, very helpful and polite as he educated me on the proper setup of the clutch and getting the right parts.

Very pleasant to deal with and highly knowledgeable. Pretty cool.

The Phantom, while in near perfect condition, had a few minor issues. Mostly surrounding the clutch.

Finding the appropriate parts for a bike like this takes a bit of work. Jay was great at getting me all the stuff I wanted/needed.

Ordered an entire new BZM clutch assembly along with 80, 79, and 78 mm bells. Springs, shoes, hardware, all sorts of goodies.

Then came the work. The bearing on the clutch cover was nuked. It'd seen its share of heat and funk from clutch dust. As I'm removing it in the press I notice that one ear of the cover is flexing more than the others. The bugger had a crack. I played with it and it fell right off.

This is a part only available from Italy so what to do?

MAKE YOUR OWN!

I measured everything and whipped up two drawings in MasterCam X3. Wrote my tool paths, set up a piece of 7075 AL and went to making some chips.

I think the OEM part was first turned in a lathe to create the radius on the outside finish. I could have done that on my CNC turning center but it would of required a lot of setup work as I typically use only collets in my machine. Changing to a chuck is about a 2 hour process and it sucks doing it.

I generated a revolved solid model, converted it to a surface, and used a scalloped surfacing tool path instead.

Here's the original part and the one I made:





As you can see I added a little meat to mine to aid in the long term durability. The OEM part was pretty thin right at the transition from the legs to the bolt boss. I increased the thickness of the material here another .05" to strengthen it by creating a domed radius on the top of each leg. . I also widened the 4 legs to give it some additional strength where it ties into the center bearing support.

I don't have an M5x.8mm tap so I'll make a trip this am to a tooling vendor so that I can finish this up. Going to replace the mounting bolts also just so everything is ship shape.

Fun stuff!




Wow, i like your bike where did you get that???
i have a couple of parts here let me know if you need some clutch or other parts...
 

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Discussion Starter · #8 ·
Yeah, you got a few parts alright! lol.

I think I'm in good shape now.

Thanks.

C.


As for the bike. The previous owner had it built to order by the factory in Italy. He then imported it here to the states and raced it a few years. PB down in the SE are pretty dead so he decided to let it go.

It's a GP Phantom. Recognized as one of the top shelf bikes for this sort of thing. Only one of its kind in the US so I'm told.

C.
 

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Yeah, you got a few parts alright! lol.

I think I'm in good shape now.

Thanks.

C.


As for the bike. The previous owner had it built to order by the factory in Italy. He then imported it here to the states and raced it a few years. PB down in the SE are pretty dead so he decided to let it go.

It's a GP Phantom. Recognized as one of the top shelf bikes for this sort of thing. Only one of its kind in the US so I'm told.

C.
is it Jose drapeau is the owner before from tennesse? i remember he's the only one who had a phantom bike back in 2009
 

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That Lucky 7 frame and some other parts on my avatar bike I got from Yong, I believe. Somewhere Mid USA,lol.
 

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PBP SENIOR M!LKER
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2,445 Posts
I wanted to take a moment and extend a big Thanks to Jay at Tsunami for his help yesterday. He was very, very helpful and polite as he educated me on the proper setup of the clutch and getting the right parts.

Very pleasant to deal with and highly knowledgeable. Pretty cool.

The Phantom, while in near perfect condition, had a few minor issues. Mostly surrounding the clutch.

Finding the appropriate parts for a bike like this takes a bit of work. Jay was great at getting me all the stuff I wanted/needed.

Ordered an entire new BZM clutch assembly along with 80, 79, and 78 mm bells. Springs, shoes, hardware, all sorts of goodies.

Then came the work. The bearing on the clutch cover was nuked. It'd seen its share of heat and funk from clutch dust. As I'm removing it in the press I notice that one ear of the cover is flexing more than the others. The bugger had a crack. I played with it and it fell right off.

This is a part only available from Italy so what to do?

MAKE YOUR OWN!

I measured everything and whipped up two drawings in MasterCam X3. Wrote my tool paths, set up a piece of 7075 AL and went to making some chips.

I think the OEM part was first turned in a lathe to create the radius on the outside finish. I could have done that on my CNC turning center but it would of required a lot of setup work as I typically use only collets in my machine. Changing to a chuck is about a 2 hour process and it sucks doing it.

I generated a revolved solid model, converted it to a surface, and used a scalloped surfacing tool path instead.

Here's the original part and the one I made:





As you can see I added a little meat to mine to aid in the long term durability. The OEM part was pretty thin right at the transition from the legs to the bolt boss. I increased the thickness of the material here another .05" to strengthen it by creating a domed radius on the top of each leg. . I also widened the 4 legs to give it some additional strength where it ties into the center bearing support.

I don't have an M5x.8mm tap so I'll make a trip this am to a tooling vendor so that I can finish this up. Going to replace the mounting bolts also just so everything is ship shape.

Fun stuff!



Wow Chad Nice work!!! Jumping right in!!! I dont think there could be a better home for that bike... How's the clutch working now? You get it dialed in?

Cheers
 

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Discussion Starter · #19 · (Edited)
Clutch is 100% again.



Ordered an assortment of outer bells so that as it wears I can scrunch down the ID to better fit the shoes. The foot peg assembly was being a bit of a biche too. When weight is applied it flexed enough to where the output shaft was eating the inside of the screw/pin that attaches the peg to the bracket. What I did was machine a little horse shoe shaped piece out of AL with the standoff needed to mount directly to the clutch and support the backside of the bracket. Seems to have worked well and it came out pretty clean.

Which brings me to my next project. Instead of tearing the whole assembly apart I'm going to machine 2x more outer housings so that it's as simple as a 4 bolt swap. No pressing shafts, snap rings, etc to contend with that way. Muy Beuno!

Lots to do. Very busy with gun stuff presently so the wee bike will have to collect some dust in the interim.

C.
 

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That bike looks so Sick you should hang in on the wall, for a conversation piece,lol. You keep giving me Crazy Ideas,lol.
 
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