Pikes Peak Project: Chapter five

In Chapter 2, we explained that we started this project with the help of 2 of our best customers who helped us to have 2 Buell XBRR. Andreas Kuehnle helped us to buy the bike number one. The plan was to use its engine for the race bike, while Peter Buedts lent us his XBRR to use the engine as spare one.
We disassembled the race engine and we changed several parts in order to let it in perfect conditions. Next photo shows the engine ready to be assembled again.


Buell XBRR engine parts

And here we have the engine once we rebuilt it.


Buell XBRR engine

At that time we had the opportunity to sell the XBRR bike to one of our customers, and we did it. Next photo shows the XBRR after we rebuilt it.


Buell XBRR

We sold be the bike because we had located some brand new XBRR engines, so we didn’t need the complete XBRR anymore. We bought 3 engines, which are already in our workshop.


Buell XBRR engine

Selling the bike and buying the engines meant an important delay in our project, but at the same time it allowed us to build our race bike using a brand new engine.

Now let’s talk about other parts that we were waiting for. We already received the new engine intakes, which have been milled in magnesium by Zanon, in Germany. This company made a great job with the intakes, they look perfect. The parts have a surface treatment to avoid the magnesium corrosion.
This is the intake in the milling machine:


Magnesium intake

Magnesium intake

Here we have the finished parts:


Magnesium intake

Magnesium intake

Next photo shows the Buell original magnesium intake (casted) and the new milled one.


Buell XBRR magnesium intakes

We also received the titanium wheel axles.


Wheel titanium axle

We also used titanium for the triple clamp axle. The photo shows the complete triple clamp, which has the same design of the Bottpower triple clamps that we use in our BOTT XR1 and XC1 bikes.


Bottpower triple clamp with titanium axle

More details, next photo shows one of the Rotobox Boost carbon fiber rims that we are mounting on our race bike. The valve has a sensor which gives us information about the temperature and pressure of the air inside the tyre. We will talk about our data acquisition system in next chapters.


Rotobox carbon fiber wheel with temperature and pressure sensor

Here we have an image of the bike in our workshop. We took this photo before receiving the 3 XBRR engines.


BOTT XR1R Pikes Peak race bike

We already have all the components that we need to assembly the bike. The only part that is not fully finished yet is the airbox. We keep working on it and we hope to finish it next week. If everything is OK, we should “finish” the bike in a couple of weeks and then start doing the first tests.

As always, we remember you that it is still possible to buy some of the products that Kriega, our main sponsor, has created to help us to finance this project. Here you have an example, the BOTTPOWER URBAN EDC MESSENGER BAG:


BOTTPOWER URBAN EDC MESSENGER BAG

Thank you very much to every one who already bought one of these cool Kriega/Bottpower produts!

We also want to thank our sponsors: Kriega, Rotobox, CeraCarbon, Technical Composites, Continental Moto España, Global Racing Oil, Totimport, Derestricted, Husmee Studio Graphique, Sideburn Magazine, Motorbike Magazine, Newbold’s Motorbike Shop, Intelligent Design Solutions (IDS), Team BRS / BRS Suspension Works, and the last one to join us is Work & Wear, which will provide technical clothing (waterproof, thermal, breathable) for the Kriega-Bottpower Team. The race is at 4000 meters, so it is important to be properly equipped.
Without the support of these sponsors this project wouldn’t be possible!

4 replies on “Pikes Peak Project: Chapter five

  • Charlie

    Looking good! Can’t wait to see more. Are you familiar with Markforged 3D printing. They make printers that print parts out of metal, carbon fiber, and onyx (which is a plastic and chopped carbon fiber.). You can use them for structural parts that are prototype. (single part) I have seen them do several motorcycle parts. If you go to 3d Hubs they are a list of local 3d printing shops in your area and they might have a Markforged printer. You send them the cad files and they can print it off for you so you don’t have to buy a printer for a couple of parts. https://www.3dhubs.com http://www.markforged.com

    Reply
    • David Sánchez

      Hi Charlie, thank you for your comment, it is very interesting.
      We have a 3D printer that we use everyday (and many nights). All our bikes have 3D printed parts, that means that we do not use 3D printed parts only for prototypes, we use them also for some “production” parts.
      For example the Moto2 bike that we built in 2010 had many functional 3D printed parts. Here you have an example of the airbox intake, which also supported the display and the bodywork:
      https://www.flickr.com/photos/bottpower/5048127576/in/album-72157613166396341/
      https://www.flickr.com/photos/bottpower/4751097363/in/album-72157613166396341/
      We are already working on using 3D printed metallic parts that will form part of the frames we design and build.
      I have been using 3D printing for more than 20 years, it is a technology that I love. It is clear that now is something that is spreading very fast and it is changing the way we design and fabricate everything.
      In following chapters we will show the 3D printed parts that we will use on the XR1R for Pikes Peak.

      Reply
  • Bob Johnson

    It’s great to see more progress. I am curious about the fuel capacity, will the side tanks have enough or are you making larger ones.

    Reply
    • David Sánchez

      Hi Bob, thank you for your clever comment. 🙂
      We are making a little bit bigger side tanks. We will talk about it in next chapter.

      Reply

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