My carbon Milan 4.2 build

[Wolfgang]

Weil das nicht mehr funktioniert, wenn Du mit der falschen Seite zu nah an einer Wand stehst ...

Wollt auch mal OT: mit Stummelflügel an der Seite klappt das auch mit der Wand. OT off duck und weg.

 

[MartinL]

Weil das nicht mehr funktioniert, wenn Du mit der falschen Seite zu nah an einer Wand stehst ...

An einen Umfaller auf die falsche Seite wollen wir gar nicht denken. Da kommt man nicht schnell oder zerstörungsfrei raus.

Die Scharniere müssten schon sehr leicht zu ziehen sein. Bei meinem Ausflug ins Feld auf der Seite vor ein paar Jahren war die Bowdenzughülle am SL verbogen und sehr schwer zu ziehen.

Beim 4.2 mit mehreren Scharnieren über die Länge wird das nicht einfacher, und die hinteren Scharniere sind vom Fahrer nicht zu erreichen. Eine zweigeteilte Haube mit Seitenscharnieren könnte klappen. Aber warum?

 

[Arend-Jan]

So in regards to the safety of your passenger and yourself: Please change this screw directly. The Milan4.2 applies more weight to the front wheels and with that also higher forces to the steering. Wider tires and reduced air pressure also increase the steering force. Due to the longer wheelbase you also have to steer more to get the same turning radius, compared to single seaters. So overall the steering is much more in charge with the Milan 4.2 - take that into account.

So, I just ordered something else, related to this topic of strength:
I have never been a big fan of the M6 threaded rods, for positioning the front struts.

What I now ordered are aluminium tubes, 10mm OD and 5mm ID, and balljoints with male M6 thread.
The 5mm ID is perfect for cutting M6 in, without additional drilling.


This is 4x stiffer, 2x stronger (if it's T6... if not then it's the same as the steel) and even a tiny bit lighter than M6 threaded rod
The only downside: you need longer thread engagement, compared to steel threaded rod. So that's something to be careful about.

 

[Tobbi]

Die Scharniere müssten schon sehr leicht zu ziehen sein

Richtig! Das ist aber bei dem oben gezeigten (und jedem anderen) Segelflugzeug ebenfalls so. Nennt sich Hauben-Notabwurf. Ist auch bei seitlichen Scharnieren kein Hexenwerk.

Ich steige übrigens (fast) immer von links ein, und nach links aus: Rechts stört beim Milan das Hauben-Halteseil etwas.

 

[Arend-Jan]

Ok, the nice thing about 3dprinting: It's very easy to just keep tweaking until you're happy

From right to left are the iterations.
Left-most has aluminium CNC-machined end-pieces, that I laminated some glassfiber over, that's why it's wrapped in plastic, to keep it tight
This shape can be manouvered over the wheel well, in front of the passenger headrest, and has 2x M6 locknuts for mounting the rear air suspension legs onto. When cured this can be laminated into the bike. The plastic part has only 1 function: alignment. To keep the 2 mounts co-axial and perpendicular to the bike. The print is ~25 grams only, so I may not even bother to try and cut it out after laminating the aluminium to the shell.


After putting on the glass, I had some epoxy left (I don't take risk by mixing less than 15 gram to avoid bad ratios) so I reinforced the front idler mount. Feels very solid already

 

[Arend-Jan]

Awkward laminating job

And even more difficult to take a picture of

I am also not that sure yet about the passenger seating comfort, I think it needs improvements

Final quality control by the world's cutest inspector:

 

[Suedhesse]

The only downside: you need longer thread engagement

My advice - add fat!

Spoiler

I think you would have done anyway... if you ride in the rain regularly or even in the winter with salt on the road, it will corrode and perhaps get stuck permanently without this precaution.
With some grease on the thread you won´t have problemes with that.

PS:
Unfortunately I can´t open the latest pictures, I hope it will work some time later.
Why don´t you just upload them directly in the post?

 

[flowi]

@Arend-Jan if I click on the images in your last post, I get a blue box with "imgbb.com uploading this content requires registration" message. The thumbnails here on the forum show fine though. Since the message talks about uploading I assume something went wrong on your end?

 

[labella-baron]

Me too

 

[Arend-Jan]

Thanks, something went wrong indeed. Weird, I thought I did exactly the same thing as before.

Anyway.. I'll make better pictures some other day. Just removed the plastic and I'm not happy with the carbon laminating I did. So I'll let it cure fully first and then remove + repair the pieces I don't like.

 

[Wolfgang]

@Arend-Jan,

You can upload all your pictures right here, that works great. It would also have the charm that if your pictures disappear from your upload center in a few years, they're gone — nobody will be able to find or see them anymore!

Here, though, they're cleanly embedded in your text, and even in 20 years everyone can still enjoy them.

I know many threads that include pictures like that, and then it just says "picture not found" — nobody knows which repair or making-of was being talked about without seeing the pictures.

It's really simple to upload pictures here, with the advantage that everyone can click on them, look back, see details, and so on.

Unless there are other reasons, but whatever's on the internet is on the internet anyway!

Several people before me have already pointed out that you should upload pictures directly to the forum rather than linking them, probably for the same reasons mentioned above.

Even many years from now, a lot of people will still want to look up your build, and especially
SEE THE PICTURES
Have a good time, I'll keep following along with interest,

best regards

Wolfgang

 

[Arend-Jan]

Let me test this function of the forum.
This is a picture of the world's cutest QC inspector:

So, it works, that's really nice. But there's a 20 MB total album size limit. I fear I will hit that quickly. But let's see

 

[Kurbel]

But there's a 20 MB total album size limit. I fear I will hit that quickly.

There is no need to use any albums.

You can attach the pics directly to the posting.

 

[Suedhesse]

There is no need to use any albums.
You can attach the pics directly to the posting.

That´s what I always do, even if albums are nice

But there's a 20 MB total album size limit.

I reduce the size of my Photos to 250 kB before uploading, by the way... I don´t see much difference to the original size for this usecase here.

 

[flowi]

Yes

You can also just drop images right onto your post text area.

Also IMHO it makes sense to crop to the area of interest and downscale the images a bit, eg max 1600x1200 for normal pictures

 

[Kurbel]

I reduce the size of my Photos to 250 kB before uploading,

Also IMHO it makes sense to crop to the area of interest and downscale the images a bit, eg max 1600x1200 for normal pictures

Größere Bilder werden beim Hochladen im Beitrag automatisch "auf eine Größe von 1280 x 1024 Pixel" verkleinert.

 

[Arend-Jan]

Ok

Made some more progress, as I had the day off.
Here you can see the 2x M6, where I want to mount the air shocks to:

The first attempt to laminate them in did not end up as nice as I want, so I removed most of it.
You can actually see the function of the printed bracket quite well in this picture:

I also managed to make my living room even less of a living room

The aluminium block is hiding underneath carbon in the center of this photo (but it requires a good amount of imagination to see it):

Using foam plate, I added ribbing to the side, and I put another chamfered foam block to smooth the transition to the wheel well, and then I also laminated towards the front and then over the wheel well to the other side (and onto the passanger headrest).
It looks extremely messy and ugly now, but after curing, removing the plastic and then some sanding I promise to share fresh pictures when it looks a lot better.

I also again played with my little CNC machine. These parts will mount onto the air shocks.
Tomorrow, I should receive my thread cutting mill tool, then I can cut M28x1 (or any other random size, for that matter ).

Also drove to Dronten today, and got myself some chain tube, new idlers, and an indicator relay and switch.

 

[MartinL]

I also managed to make my living room even less of a living room

How to spot a man of determination.

 

[benparke]

Ok

Made some more progress, as I had the day off.
Here you can see the 2x M6, where I want to mount the air shocks to:
Anhang anzeigen 444895
The first attempt to laminate them in did not end up as nice as I want, so I removed most of it.
You can actually see the function of the printed bracket quite well in this picture:
Anhang anzeigen 444896
I also managed to make my living room even less of a living room
Anhang anzeigen 444897
The aluminium block is hiding underneath carbon in the center of this photo (but it requires a good amount of imagination to see it):
Anhang anzeigen 444898
Using foam plate, I added ribbing to the side, and I put another chamfered foam block to smooth the transition to the wheel well, and then I also laminated towards the front and then over the wheel well to the other side (and onto the passanger headrest).
It looks extremely messy and ugly now, but after curing, removing the plastic and then some sanding I promise to share fresh pictures when it looks a lot better.
Anhang anzeigen 444899Anhang anzeigen 444900
I also again played with my little CNC machine. These parts will mount onto the air shocks.
Tomorrow, I should receive my thread cutting mill tool, then I can cut M28x1 (or any other random size, for that matter ).

Also drove to Dronten today, and got myself some chain tube, new idlers, and an indicator relay and switch.

A woonkamer literally is room in which to live. Velomobile is life, thus perfectly suited to a living room.

 

[Arend-Jan]

Oh yeahhhhh
I can now make my own threads (in aluminium, not just by 3dprinting)

The purchased tool was for 12mm thread depth maximum (2xD, very common)

But, being a man of determination, I do not let such foolish limitation hold me back.
Put the mill in my battery drill and a diamond cutting disc on the Dremel...
And after letting those tools get to know each other quite intimately the end mill can cut 18mm thread

Looks about right...

Fingers crossed, go!

Test