Aermacchi Front Hub – Part 1 with Paul Brodie

hi i’m paul brodie this is my shop mitchis behind the camera as usual welcome today we’re going to work on aramakirace break for my yield road racer i have some i’ve assembled some parts herewe’ve got a centre this centre is off a honda 450 this is the same kind of hub i usedback in 2001 when i built my bicycle back in 2001 i got a hub off a friend for 35 horses i recognise now that was a great deal because i got this off ebay and by the time itwas shored and i paid taxes and duty and all that it was about 500 bucks this is off in 1968 honda 450 twin and i happen to like this because of the length and the gape so whatwe’re going to do is we’re going to start some flaws you can see how i’ve i’ve commemorated outone flaw there’s gonna be six punctures around here because on the inside we’ve got six ribs sothe holes are gonna go in between the ribs six of them we’ve got a backing plate this is whatholds the brake shoes the brake shoes go in here i’ve got frodo liners i’ve had sitting aroundfor years these are hard to find now these are the race linings they’re lettuce they’re madein england i think they have asbestos in them better settled it down and and the endorse sheet isis going to get most modified it’s going to have have added fragments on it it’s going to getrotated and what we’re going to start out with with is the is the torque stay thisis what supports the affirms the endorse sheet onto the fork so this is the template that ihad from 2001 and i’ve marked it out so the first thing we’re going to do is go over to thedrill press i’m going to drill a series of gaps knock cold the midriff framed it back in themill because now i can i can still hold this because these features here are parallel and ican take an end mill and i can fix that smooth then filing and that’s when i cut the outside outso first of all we’ll go over to the drill press okay i’ve got a two pound let’s mallet what happens that’s what i craved so that precisely determines it a little easier so we’llgo back to the mill now and i’ll maybe expend half inch goal mill and i’ll go along alongto the line i’ll put on some cutting oil now so that it’s on there and idon’t have to add much as i go i’ll switch to a little a little one quartercarbide end mill it’s a four flute there are a two flute four flute maybe more but the common one sowe’ll move fast now we’ll go up to up to 2000 rpm okay so that’s the basic shape it’s uh it’snot real smooth but it’s it’s closed so we’ll go to the bench sin now do a littlebit of registering not not too much but a little i’ve got a half round filehere it’s a little bit coarse got my deburring tool i’m going to form the inside smootherlater you get the idea now what i’m doing though okay let’s go to the drillpress we need four eight mill faults i’m gonna instruct a smaller hole first and theni’ll finish off with the eight mil that’s usually better than just going right from the centerdrill up to eight mil so i’ve got something now eight mil drill i can drill in thattrick very it doesn’t “ve got to be” imperial next pace is the bandsaw we’re gonna we’regonna represent the outline over on the bandsaw we’ve got a red strand and we’ve also got ascribe line and the scribe text was made by a pair of dividers and so the scribe indication is moreaccurate because it went off the center punch hole and the blood-red line went off the cardboard templateso if you think that i’m following the red strand and not doing a good job that’s not what’sgoing on there’s a scribe position i’m following i like that figure let’s go do a littlefiling and then we’ll move on to the hub i’m consuming my my father’s aged wood filesee wood file on a tower and it acts just fine likewise when you’re filing you cansee how how straight you cut with the bandsaw if you’ve got a lot of highs and lows it meansthat you didn’t follow the line very well so this is not bad i’ve had a littlepractice so i’m filing a radius so this has a large radius here but this isfairly flat so i’ll start filing around here and once again i’m going away from the radius okay so now i’m connectingthat flat with this flat okay i’m just going to knock off thebrewers now i’ll use a small file it just takes off any sharp-worded spot so idon’t chipped my hands if i’m gonna handle it this is just a little bit of used scotch brite so after it’s all polished up after the edges areall smoothed up i think it’s going to look quite nice on the bike i’m energized about building a racebike okay so next place is to go over to the mill we’ve got to set up the rotary table slant thehead a little and we’re going to drill holes in the hub to save weight maybe what we’ll dofirst of all is to weigh the hub and then we know how much metal we taken away from how much weight savinglet’s do that okay it’s direction in time and the hub is 2873 grams let’s go save some value i’vegot an axle here it’s a 15 millimeter axle which fits the hub and i weld it on a boss andthe boss goes in into the rotary table are you able see how it fits into the rotary tablelike that and then i’ve got a six mil clamp that goes in from the back so now right inthe middle of the counter i got a 50 millimeter axle so that’s what i use to mount the hub and thenthe hub is is concentric that’s a good thing i’ve got this distinguished with a felt confine but that’sjust by eyeball when i came over the top see how i’ve got a felt pen label there and then i kindof went over here by eye and then it departed up to the middle by gaze but i would like it to be rightin the middle of these so i think what i’m going to do is to i’m going to drill a puncture right downthrough the centre for human rights of that rib and then it’s just got to be a really small pit and then i’ll knowthe exact core and then i can line up off that there we go i’m gonna see ifi can teach a gap right there there we go we’re through okay so inspect my string waspretty close to the center but now i know where the center is so the first thing we’re goingto do is we’re going to drill six excavations with a inch and 5 16 hole checked and then we’ll use theboring mill or the yeah at the boring premier and we’ll make a nice slouse because this doesn’tmake a nice cut gashes but it’s kind of rough that’s about eight grades right there and ican see a little bit of space over on that side you can threw that up it’s pretty closeso it needs to go just a little more that’s nine measures right there can you see itlooks pretty flat with the surface i’m gonna primed mount my magnitude now to zero because we got six punctures so sixholes intends every every 60 degrees it actually makes a nice cut it’s an almost brand new hole discovered but i amgoing to go a little bit wider than that anyway that’s the first flaw so we go 60 degrees nowevery 60 severities because we wanted to do six excavations we’re so to swap implements now we use use a boring prohibit open the holes up merely a little bit more can yousee how it’s moving out it’s a pretty neat tool and the scale is in thousandths it is notnot metric just in case you were wondering so if i look at the spacing now what i gotto do is the line see how there’s more space over here than here so i need to bring thetable this lane i need to move the tool out okay a bit more okay see how it’s hit it’staking a little cut off the back there and nothing off here soi’ll is moving forward to a little bit okay so we we are basically scented youknow within a marry thou so and we have to you can you can see how much it’s going to cut all around let’s take a cut and appreciate what happensokay see that okay i’m going to do something you can see how it’s vibrating you can seehow it’s offset and it’s out of balance so what i do for that i make this it’s justan extra piece of metal and i kept it now and that’s my counterweight butwhat i have to make sure is that it looks like it’s just going to clear it’s just just going to miss i have to keep aneye on that make sure that it doesn’t move out so i set an extra allen fuck in there so that’smy counterweight so it should be smoother now so as i go down it is going to get closerthere i’ll i’ll listen for any interferences there so that’s smoother and that’s trimming neatly okay and so the racket you discover there that kind of a tap racket that’s where itsee are you able see here that little portion of assigning that hangs down that’s the noisesit’s hitting that that’s an ended slash and we should not we should not affected so now we’re goingto go 60 positions and we’ll do this five more experiences our next step is to drill a smallerhole in between the spoke faults so it’s a 40 fault motif so each side has has 20 so that means i need to mark a piece of paper or cardboard every 18 severities so that when i movethe rotary counter i know what 18 is each time i find the middle it’s rightabout there you can mark like that so that’s the size of my instruct so let’s just findlook at that that fits pretty nicely right there so let’s see where we want this this isvery very precise what we’re doing here so that’s where we’re going to settle the hole andit’s a short drill so it’s not going to flex so what i’m hoping is that we don’t have to doa sensor drill a captain puncture and then that instruct because this is every 18 degreesso we’re gonna set this up now and i’m hoping that one one instruct goes rightthrough i took a piece of cardboard and i made i made my my phone my calculator and i markedout every 18 positions so i’m gonna look at this and i have to move move the rotary table forevery pit that’s why i only want to do this once because otherwise it just takes longerso what i’m doing now is to is to reposition it’s kind of an eyeball thing it’s justa lightning defect if i touch down gently with the teach we’re going to see how we’rescented i’ll make any faster there we go see that appears so let’s take a chance let’slet’s drill one loophole and we’ll appreciate what happens oh that one that looks fine and it’s not hittingany shoulder or anything it just goes through okay we’re wheel them so we’regoing to go to 18 severities now and that should be right in the middle again 108 this is the last hole on this surface excellent i think that looks great so now we have to do the otherside so i need to mark it and then this one won’t be held the same way because it’s different so we’ll have to seewhat what’s going gonna go on now okay so we’re on zero that’s good it looks like it’s in the middle okay excellent no screw-ups i want to know how much itweighs i’m very very curious so two thousand 716 so we have saved 100 0.4 7 5.157 grams so pound well it’s less than half a pound but regardless and that’s unsprung force it’sit’s rotational mass so it all matters i like the ogles of that that’s a good lookinghub we had planned to do more filming but we have a windstorm and a tree fell out and welost our power so we’ll have to continue next week but expressed appreciation for for watching havea great week and stay safe thank you.

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