Sunday, December 5, 2010
My new Steel version is on the left, the aluminum OEM on the right.
The rear swing arm assembly I got on Ebay said that it had the pivot bolts in it. Except 1 (of the 4) was missing. So back to ebay and found 2 bolts listed for an R1150/R1100 rear swing arm. Got em for $20 (inc shipping) and thought all was happy happy. Well nooooooo. The 1100 has a different thread than the 1150 and these turned out to be 1100 bolts. Same in every other way. Go to the Web and find that I can just order the one I need from Max BMW for $28. Except you can't just order one, you need to order two! So with tax and shipping it turns into ~$80. I have a lathe and some steel (the OEM are actually hard anodized aluminum) why not make one? So I did, and spent a day to make a $28 part. Of course the other justification for this is that it would have taken 10 days, at least, to get it from Max, as I'm sure they didn't have it in stock. So I feel a little better, and it's always fun making stuff too. And broaching them for the 12mm Hex Key was included.
Friday, December 3, 2010
Transmission mounted to the engine with an almost viable adaptor plate. the modified flywheel with clutch mounted all seem to fit. I have to make a few adjustments and I can machine the final piece out of aluminum. I'm also proud of the new engine stand I made. Sometimes it's the simpler things....
Thursday, December 2, 2010
MDF. This is to make sure I have all the hole locations correct and that the width is right so that the input spline of the transmission has enough engagement with the clutch . If this is correct then the finial piece will be milled from aluminum. That is a BMW Clutch mounted to a heavily modified Smart Flywheel. I'll try to post images and a description of the process of mounting the clutch pack when I can find the images I took during the process and when I get a bit more sleep (see previous post).
Thursday, November 4, 2010
Sunday, October 17, 2010
I needed to get the clutch and pressure plates out of the flywheel. I plan on mounting a BMW R1150 Clutch pack for a number of reasons. I thought I could get away with drilling out a few riveted pieces and it would come apart. The smart clutch isn't a serviceable item. Mercedes intends for the entire flywheel and clutch assembly to be replaced as one unit and therefore there is no way to disassemble it. I can'tt even figure out how they got it together. There are no bolts or weld marks, and there is no room anywhere that I can see to get tooling in to the assembly. My best guess is that it is in fact pressed together. The only clue to that is that the starter ring gear appears to be presses on to the cast iron flywheel so maybe they have a process for pressing the outer plate (the one that holds the spring diaphragm) over the clutch into the flywheel.
Wednesday, October 13, 2010
This is what’s left of a 1996 BWM R1100GS. It's been sitting around collecting dust since 2000 and recently I had hoped that it would provide the parts I'm missing to mate the 2004 R1150RT trans to the final drive and also supply a clutch I can use as a mock up. But nooooo. I seemed to remember reading about stripped splines on 1100 transmission shafts. I guess this is why BMW changed the input spline of the 1150 transmission to 23.5mm from 22.5mm. Likewise the output shaft is also larger than its predecessor by 1mm so I can't use these parts here. However I still have a plan for them. let's see how much more dust they can collect till they’re needed.
Monday, September 6, 2010
Wednesday, August 25, 2010
Saturday, August 21, 2010
Going throught all the sensors one by one to make sure they are all working and the ECU is seeing the right signal. Looking at the VR sensor for the crank and the hall effect sensor for the cam position.
a vidieo of the signal from the VR crank sensor: