• Husqvarna Motorcycles Made In Sweden - About 1988 and older

  • Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

HVA-Factory Clutch covers! R & D continues...

hva-factory

hva-factory

CH Sponsor
Due to popular request, and the fact that we are down to our last few, I am now in possession of two new casting patterns.
They have been produced by scanning new original covers, creating a computer model and scaling up to cope with the shrinkage of the Aluminium when they are cast.
One is for the 5 or 6 spring clutch Aircooled Primary kick bikes and one is for the 5 or 6 spring clutch Liquid cooled bikes.
I am off to the foundry tomorrow to have a first attempt with the new patterns. When we have De-bugged the prototypes, we will do a production run. They will not be available until the new year though, as all this takes time and a lot of money!!!

Andy Elliott.P1010013.JPGP1010012.JPG
 
Glad to hear that. I go to great pains to repair original covers and it is not easy after someone welds the magnesium.
 
HereP1010019.JPG is the 'First-off'. Need to increase the draft angle in some areas - so that the pattern will release more easily:
 
Looks good for a raw casting. How much draft was used in your pattern? I would think about 3 degrees draft in deeper sections would give good release with a good release compound used in the sand cavity.
 
Andy,
This is cool. Thanks for working on this.

I've had a clutch cover experience with my 87 430 WR.
The clutch cover always needed two gaskets to seal to the case. Pulling it all apart and trying another clutch cover revealed the original cover was a defective casting or poor finishing. Not defective by much, but enough that two gaskets were needed. Just showed me how close the tolerances are!

Good luck. I am following your progress.
Dave
 
Thanks guys.

Yes, the draft angle for sand casting needs to be greater than they have got away with - die casting the covers. I will work on filling the offending areas on the patterns with car body filler next week and tapering off some edges. This is always a slow boring process. It will consume many hours before they are ready for a production run.... I want to improve the surface finish too, as this will help with the mould releasing and give a better finish to the case.

Andy.
 
I am glad to see you are bring out the raised features of the OEM cases. That is the main reason I try to restore them with JB Weld. It sands and blends well and takes engine paint as well.
 
May I suggest that You include the Pin that is pressed into the Cover that passes threw the Shifting Spring. No wanting to ruin my old cover pulling it out I made my own Pin. However I made it to short not knowing exactly what it purpose was at the time. It took quit a wile to figure out what was wrong with the Shifting.
 
Yes, All the covers we supply now have the dowell pin fitted. We have 3 - 5 spring clutch Air cooled covers left at present and more 5 spring clutch liquid cooled covers. The new ones will not be ready for some time yet as I am having a new hip fitted in 2 weeks time****************************************

Andy Elliott
 
What about designing a modified cover that includes a removable clutch cover. I always thought that back in the day.
 
hva-factory said:
Due to popular request, and the fact that we are down to our last few, I am now in possession of two new casting patterns.
They have been produced by scanning new original covers, creating a computer model and scaling up to cope with the shrinkage of the Aluminium when they are cast.
One is for the 5 or 6 spring clutch Aircooled Primary kick bikes and one is for the 5 or 6 spring clutch Liquid cooled bikes.
I am off to the foundry tomorrow to have a first attempt with the new patterns. When we have De-bugged the prototypes, we will do a production run. They will not be available until the new year though, as all this takes time and a lot of money!!!

Andy Elliott.View attachment 32804View attachment 32805
Click to expand...

Are the patterns from a 3D printer?
 
Yes, but not your regular desktop one! These are from an advanced technologies Lab that has 3 worth about 1/3 rd of a million £ each!!!

You get what you pay for - so they say...

Andy
 
Had a chance to see this year my first 3D printer. I know it was just a smaller one but to see the part samples for prototypes was amazing.

To see a ball bearing printed and and made completely made assembled was amazing. Of course this was powder, but the future with powdered metal just boggles me.

When prices come down in a few years, just think what can be made. Think of this part being made/fused from the center out.


( gears made of powdered metal for power equipment (made under pressure) has been around for years).
 

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  • 3d printer samples.jpg
    3d printer samples.jpg
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GaryM said:
Had a chance to see this year my first 3D printer. I know it was just a smaller one but to see the part samples for prototypes was amazing.
To see a ball bearing printed and and made completely made assembled was amazing. Of course this was powder, but the future with powdered metal just boggles me.
When prices come down in a few years, just think what can be made. Think of this part being made/fused from the center out.
( gears made of powdered metal for power equipment (made under pressure) has been around for years).
Click to expand...

Yes, really amazing.
I'm amazed by the same thing, putting round bearings inside an assembly. Very cool. A lot of new possibilities coming.
 
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