Aprilia MXV 450 : Motocross full carbon project completed.

Author	Message
Thanasis	Thanasis posted 9 Years Ago HOT Topic Details
Group: Forum Members Posts: 36, Visits: 234	After 1 year, many hours of work, 16 moulds, some carbon parts born for scrap, some of them with very short riding life, some sticking conditions from moulds to parts and vise versa, I finished my motocross carbon project! From plastic: To carbon: The loss of weight was not the main issue, the main goal of project was to make the rear fender stop cracking while riding in heavy mud and specially with supsension bottoming on bigger jumps. In muddy conditions the rear fender was bound to broke damaging also the rear side panels. Making just the rear fender in carbon didn't help very much the situation. Final solution achieved by making the three seperate plastic parts (rear mudgard and the two side panels) just in one piece. A three piece mould was needed for this purpose: Unfortunately the first mould produced a slightly wrong dimensioned part (with a lot of aesthetic problems also). The one piece tail could not fit correctly in the subframe. Both mould and part go straight to trash. Starting from scratch the mould, this time the 3 plastic parts were tighten in the subframe and the mould was produced with all of them sitting in the right position. The mk.1 part was good enough but not perfect. it last a lot of motocross riding hours but failed a little bit in very heavy mud. It was the time for mk.2 rear fender, this time more stiffer and 100 grams more heavier than mk.1. Mk.2 turned to be perfect and very good looking. It is tested in the mudiest conditions with success! The fever of carbon modification was all over me and the rest of the parts were mend to be carbon also.... Edited 9 Years Ago by Izo78
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hayeglas	hayeglas posted 9 Years Ago HOT Post Details
Group: Forum Members Posts: 1, Visits: 40	Nice work mate! I thought about doing the subframe as well a while back (same bike, HayeSM from aprilia forum). I was planning to make the mold while the subframe is mounted the bike, to ensure the dimensions are right. What kind of inserts will you be using for mounting it to the frame? I thought about a adjustable bal-joint of some kind, this would be a similar idea the 08 vdb bikes had on their subframe. Will you be using inserts for the exhaust mounts as well? My idea was to make the side of the subframe (which is normally open) smooth instead of a small extrusion (hope you know what i mean) but this would mean the mounings of the exhaust would need to be bonded in later or making a small extrusion at this place
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Thanasis	Thanasis posted 9 Years Ago HOT Post Details
Group: Forum Members Posts: 36, Visits: 234	Hi, great to see other MXV lovers around! The subframe project started because recently both upper beams of subframe were cracked near the joint with the frame, as a result from a very very heavy landing involving neck injury after a tripple jump go bad. The subframe was welded and repaired, but since the subframe is the only spare part concerning the MXV that Aprilia has discontinued, I though as a good idea to try to replicate in carbon. The idea is to close the two side triangulars of the subframe and the top rectangle and leave open the bottom side (red areas) : For connecting the frame to subframe, I am thinking of "T" bushings, something like the photo below: For the rest of the mounts that are less critical (rear fender, side panels and exhausts) I think bonded fasteners will do the job: Any other ideas especially for the 4 mounting holes for fastening it to the frame are welcomed. Edited 9 Years Ago by Izo78
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Aprilia MXV 450 : Motocross full carbon project completed.

Izo78 - 9 Years Ago

and the rest of the parts... front fender (-100gr from the plastic which is weighting more or less...

Izo78 - 9 Years Ago

Radiator covers and air filter cover : Lateral number plates : Original carbon engine guard...

Izo78 - 9 Years Ago

The new project to complete is the aluminium subframe. It is a risky project, if something goes bad...

Izo78 - 9 Years Ago

Some really good work there!

scottracing - 9 Years Ago

Thank you, So many hours spend...but so much pleasure coming from the sentiment of creativity.

Izo78 - 9 Years Ago

Hi ! Very great job !! One question : What do you put around the models to make the mold (the...

Julien - 9 Years Ago

Hello Julien, thank you. It is very simple, follow the steps of mould creation videos available...

Izo78 - 9 Years Ago

Nice work mate! I thought about doing the subframe as well a while back (same bike, HayeSM from...

hayeglas - 9 Years Ago

Hi, great to see other MXV lovers around! The subframe project started because recently both upper...

Izo78 - 9 Years Ago

Good work so far.. The subframe would be my only worry. I made a one piece fuel tank and monocoque...

morepower - 9 Years Ago

@ morepower Thank you for your advices and conserns. This is my main concern also, to make it as...

Izo78 - 9 Years Ago

regarding the 4 mounting points for the frame mounting, I would have some machined, in a shape that...

Dravis - 9 Years Ago

[quote][b]Dravis (15/12/2016)[/b][hr]regarding the 4 mounting points for the frame mounting, I would...

Izo78 - 9 Years Ago

Nice work! You have done really well with the moulding of somechallengingshapes :cool:

davro - 9 Years Ago

nice job mate! had a mxv too too bad i sold it:(

Thomb - 9 Years Ago

[quote][b]Thomb (20/12/2016)[/b][hr]nice job mate! had a mxv too too bad i sold it:([/quote] Oh...

Izo78 - 9 Years Ago

So I found finally some time to finish the mould. It is ready to go!

Izo78 - 8 Years Ago

looks great, any pics of how you make the mould edges of the parts with the plastic?

Thomb - 8 Years Ago

[quote][b]Thomb (28/01/2017)[/b][hr]looks great, any pics of how you make the mould edges of the...

Izo78 - 8 Years Ago

How it's going.

Shaneer22 - 8 Years Ago

[quote][b]Shaneer22 (06/02/2017)[/b][hr]How it's going.[/quote] I have kept the subframe project...

Izo78 - 8 Years Ago

please make some pics! always nice to see.

Thomb - 8 Years Ago

[quote][b]Thomb (16/02/2017)[/b][hr]please make some pics! always nice to see.[/quote] I have a...

Izo78 - 8 Years Ago

Well done mate, really looks nice :)

Thomb - 8 Years Ago

Nice video! You have certainly made some impressive composite parts!

Warren (Staff) - 8 Years Ago

[quote][b]Warren (Staff) (22/02/2017)[/b][hr]Nice video! You have certainly made some impressive...

Izo78 - 8 Years Ago

A tiny leak in the bag kept me asleep untill 4 o'clock in the morning....but it seems that the...

Izo78 - 8 Years Ago

Just for future knowledge, core materials are not ideal in mounting points. They tend to have lower...

Hanaldo - 8 Years Ago

[quote][b]Hanaldo (07/03/2017)[/b][hr]Just for future knowledge, core materials are not ideal in...

Izo78 - 8 Years Ago

nice job mate want to see some high res pics with those parts on the bike :w00t:

Thomb - 8 Years Ago

Finally the subframe is ready : It went pretty good in every aspect,...

Izo78 - 8 Years Ago

What ever the result of this piece will be, I will be back with a Mk.2 subframe and giving special...

Izo78 - 8 Years Ago

Weekend is over and MX training went pretty good! Thumps up for the carbon subframe! During...

Izo78 - 8 Years Ago

That is great news; I can imagine that it was a little tense whilst building up confidence in the...

Rich (Staff) - 8 Years Ago

nice work!!

Thomb - 8 Years Ago

Here it is the Mk.2 version of carbon subframe. Better than the first version in every aspect, both...

Izo78 - 8 Years Ago

Looking good! I like the use of carbon kevlar on the inside to give it a bit more impact resistance...

Warren (Staff) - 8 Years Ago

And a video of the bike with the carbon subframe installed :...

Izo78 - 8 Years Ago

looks so good!!!! how much layers did you use for the plastics?

Thomb - 8 Years Ago

[quote][b]Thomb (17/05/2017)[/b][hr]looks so good!!!! how much layers did you use for the...

Izo78 - 8 Years Ago

The bike looks awesome! Did you use the Uni-mould mould making system?

ThomPa - 8 Years Ago

[quote][b]ThomPa (30/05/2017)[/b][hr]The bike looks awesome! Did you use the Uni-mould mould...

Izo78 - 8 Years Ago

I am back with a new mould for the subframe of Aprilia MXV, easier to work with especially during sealing the vacuum bag and with provision for extra material in the mounting points. Also it is made....

Izo78 - 6 Years Ago

Very nice job! My one comment would be 15mm is insanely thick, I feel that could be refined further. For perspective, I was involved in a mining project here building carbon fibre haul pack trays for...

Hanaldo - 6 Years Ago

Thank you Hanaldo!... he he he, yes indeed, it is insane thick, especially comparing to aluminium that is much smaller (which it did cracked and welded many times before after some hard suspension...

Izo78 - 6 Years Ago

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FRTCARBON - 6 Years Ago