Thursday, August 25, 2011

Well it has been too long since my last update.  But it has been busy and exciting. 

I have been doing a lot of CAD since my last update.  Most of it has been for the design of new Welding Fixtures for the latest racing kart chassis my employer will be producing.  It is the first time that we have designed the entire chassis welding jig in CAD (Inventor).  So far it seems it has been well worth the effort.  Unfortunately I can't post any images of the CAD models or the finished Jig as they are not really my property.

I can post a pic of another project I have been working on.  Since my last blog update my wife and I got the conformation that she is pregnant with our first child.  So far things have been ticking along nicely but time is moving fast and our baby will be here before we know it.  We are due in late November and so most of my spare time has been spent getting our house into shape and ready for kids. More importantly, I cleaned up my Minimoto Racer and have started some planning for the first go kart build. 

                     Here is a 3D image from our 20week ultrasound.  (About 6weeks ago). 

I have made a start on my design for the ESP Competition Stage 2.  So far I have a nearly completed front wheel.  Nothing too exciting, I should be able to post some images in the next couple of weeks.  I thought I may have missed out on submitting for the second stage but they still haven't announced a due date yet so I may still be in with a shot. 

I stumbled onto a couple of great Solidworks Surfacing tutorials in the last couple of months and spent a couple of nights starting off on the Camaro Tutorial.  I hadn't ever worked with surfaces before so it has been quite a good learning experience.  Whether you use Solidworks or Inventor I'd recommend checking out the links.  I'm looking forward to getting some projects finished so I can get back onto finishing the Camaro off.

Here's a screenshot of my Camaro (well some of it anyway) after a couple of hours work.

Thanks for reading.  I hope to have another Blog update soon with some pics of my ESP Stage 2 entry, my Camaro and maybe the beginnings of a Baby Kart Chassis for our little one.

Saturday, April 30, 2011

Well it's been a while and time for a fresh update.  Unfortunately I've been very busy but haven't spent a lot of time on my computer doing any CAD work. 

One exciting happening is the recent opening of the 2nd Stage of Intercad's ESP Competition.  I will be  downloading the files and entering the 2nd Stage tomorrow.  I look forward to getting started on working on a design for the wheels and drivetrain and hopefully I can come up with something innovative and can have a bit of fun with this stage.  Be sure to check out the ESP website and if you are an Australian or New Zealander get your entry underway for the 2nd Stage.

I went to the 2011 Broadford Bike Bonanza on the Saturday of the Easter long weekend.  Broadford is a motorcycle racing complex in Central Victoria and they host an anual motorcycle event that features Motorcross, Off-Road Enduro racing, Speedway/Flat Track racing and Road Racing all at the same venue on the same weekend. 

I originally was drawn to the event when I heard that 1 of 10 Brtten V1000's was being bought across to be ridden at the event by fomer Motorcycle World Champion Hugh Anderson and that also Rod Tingate would be in attendance with his Replica of Kim Newcombes Konig Racebike.  The Britten V1000 and the original Konig were for the most part designed by very talented and visionary New Zealanders.  John Britten for the V1000 and Kim Newcombe for the Konig.  Unfortunately both of these brilliant men had there lives cut way too short.  This made seeing these bikes on track in person all the more special.   Below are some pics from the event of Rod's Konig and the Britten V1000.

I was happily surprised when I arrived to find that the Irving Vincent Team was attending and fielding several of there racebikes.  Including their Racing Sidecar entry and track debuting their Irving Vincent 4 valve V twin engine.  The Irving Vincent bikes are always beautifully turned out and use a re-engineered version of Phil Irving's 1946 push rod V twin Vincent engine.  Power output is up around 160 - 170hp.  It was certainly a thrill to see Hugh Anderson on the Britten V1000 and motorcycling journalist Alan Cathcart on the Irving Vincent running around on the track together.

Below are some pics of the HRD Engineering - Irving Vincent racebikes.

Unfortunately I didn't take pics of all the great machinery running on the day.  I did manage to take a couple of pics of a beautiful Boardtracker Indian, a very nice Replica of a Ken McIntosh framed Suzuki and of Ian Drysdale's "Drysdale V8" bike.  Alan Cathcart took out Ian's bike in the 2nd Celebrity session on the Saturday afternoon. 

Thanks for checking in on my blog.  Hopefully the next installment will include some new CAD work.

Wednesday, March 16, 2011

ESP Competition First Stage Winner!!!!

Apologies for the large break in my blog posts.  It has been a hectic couple of months since my last update. 

In late 2010 I posted screenshots of my initial entry for Intercad’s Electric Superbike Project Competition. 

After submitting my entry in November I received an email from Intercad very late in December to inform me that the judges had shortlisted my design along with 2 other competitor’s designs as winners of the ESP chassis design stage of the competition.  Intercad didn’t provide any details of the other selected competitors designs but did inform me that the shortlisted competitors would have the option of using the month of January to update or modify our designs to better suit the goals of the competition.  Overall the feedback was very positive on my initial design with the modifications the judges asked me to make focusing around me replacing the girder front end with a conventional set of off the shelf telescopic forks.  The judges also asked me to indicate how I would approach mounting the batteries in my design.  I opted to update my design and spent much of my Christmas holidays and the month of January working away to create my BergerHaus Mk2 design. 

I decided to take a different approach with my updated chassis and focused on a chassis design that would not restrict or limit the width of the battery boxes.  I intend for the Carbon Fibre battery boxes to be used as stressed members in the design and they have been designed to be somewhat flexible in their design to allow for modifications to suit the battery technology available when manufacturing commences.  The bodywork and battery boxes shown in these screenshots are not final as they will be designed/finalized at later stages in the competition.  They are included to indicate how I anticipate them to mount on my BergerHaus chassis.

Well after 6 or so weeks of waiting all the hard work and late nights has paid off.  I was contacted by the Intercad earlier this week with the fantastic news that my frame design had won the first stage of the Electric Superbike Competition and it will be used in the final design and construction of the bike.  After talking to Intercad it was organized for me to attend a small presentation ceremony at Intercad’s Victorian office in Glen Waverley last Friday.  At the presentation I had the pleasure of meeting some of Intercad’s key personel and discussing some aspects of the competition over lunch.  I was then presented a Certificate recognizing me as the Winner of the first stage of the ESP competition by Julian Spencer, Intercad’s National Product Manager. I was then presented my new Hewlett Packard Z200 Workstation which looks great and I can’t wait to install it in my office and begin working with it.  Currently I use a Hewlett Packard 8710p Notebook for all of my CAD work and I’m confident I will be as happy with my new Z200 workstation as I am with my HP Notebook.  Once the presentations were complete we took some photos of me posing with my prizes and those Intercad personel that attended the presentation.  If you are interested I recommend you keep an eye on the ESP blog website , it has just been updated with the photos from last Friday and further information on the following stages of the competition. 

I’d like to personally thank Intercad for proposing and running the ESP Competition as well as the projects technical partners Triple 8 Race Engineering and Racetech Steels.  I’d also like to say a special thank you to Hewlett Packard for supporting the ESP Competition and putting up the HP Z200 Workstation.  I will certainly put this machine to good use in the near future.  I have already loaded Solidworks onto it and can't wait for the next stage of the ESP Competition to commence. 

It is a huge experience for me and I am very excited about being a part of this exciting project. 

Enjoy the screenshots and please continue to check for updates.

Sunday, December 5, 2010

250 Single Throttle Body

Here’s some screenshots of a Prototype throttle body I was designing earlier in 2010.  If it does make it to prototype production it is destined for use on a single cylinder 250cc four stroke kart engine.  I was asked to produce this model in my own time by a workmate some time ago. I felt it would give me a good opportunity to gain further experience and work on an actual project that may make it to production.  At this stage the project this throttle body was destined for has been put on hold so it has been left in the state you see it.  Hopefully we will get some good news in 2011 and the project will be back on again and we can see it go into prototype production.  I will post updates if it does.

Wednesday, December 1, 2010

"One Man's Dream". The Story of the Britten V1000.

I recently purchased 2 DVD copies of "One Mans Dream"  from Ben Ruffell to replace my very worn out VHS copy.  I was very excited to see the extra features and would highly recommend the DVD to anybody wishing to be inspired by a truly innovative man and his efforts to build a world class racing motorcycle from his garage in New Zealand.  A brilliant documentary about the very inspirational man who was John Britten.

Check out Ben's website @ to order the "One Mans Dream" DVD.

Below is a photo my wife Michelle took of me with one of John's Britten V1000's when we honeymooned in New Zealand last year.  This bike is housed in a small Britten Motorcycle museum set up at the rear of the Brittco Developments building in Christchurch.  Being a very big Britten fan, getting to see the museum was certainly one of the highlights of my trip.  Check it out if you ever have the oppurtunity, I highly recommend it.

My Electric Superbike Competition Entry.

This intstallment in the BergerHaus Design Blog is four screenshots of my very last minute entry for Intercad Australia's "Design an Electric Superbike Competition". The competition is being held in a few stages but the finished goal is to design an Electric Superbike (like a TTzero bike but for the road).  The first part of the competition is to design the frame/chassis to be used in the construction of the bike.  It is being run by Australia's major Solidworks distributor Intercad and is only open to Australian or New Zealnad citizens.  The winning entry is going to be built by one of our top race engineering companies (Triple 8 Race Engineering) and will be sold at auction for charity.

Check out the Electric Superbike webpage for further details & updates.

I am a little disappointed with my entry and I wished I'd had more time and would have also liked more information regarding the battery specifications/quantity/mass etc. when designing.  It has been good fun though and is the first time I've had a go at a major project on Solidworks.  Whether I win or not I am going to finish out the design of the bike anyway because it has been quite a good learning experience.  I chose to use Chrome Moly for the chassis construction as one of the primary sponsors of the competition is RaceTech Tubing here in Australia and they specialise in High strength Alloy tube supplies.  Chrome Moly is also a well proven material in other similar applications and is relatively straight forward to fabricate.

Once the winner of the first stage has been anounced I will most likely commence work again on my chassis design regardless of the outcome, (win or lose), this will include moving the motor position to make more room for batteries.  As an added bonus the winner of the Frame design stage will get to work with Solidworks Technicians and Triple 8 Racing's Drawing Office Manager Ian Draper to work though and validate their design.  This would be a very good experience indeed.

                                                  Enjoy and please feel free to leave feedback.

Tuesday, November 30, 2010

My Minimoto Racebike.

My first installmnet in the BergerHaus Design Blog is some screenshots of my first major CAD project.  Having already learnt some CAD basics on Inventor and Solidworks I decided to model my Minimoto Racebike on Inventor to gain more experience and knowledge. I also hoped to add the Minimoto model to my folio/resume for any future job applications.  I decided on my Minimoto as it was small enough to dismantle and bring the components into the study of my home to measure and model.  I used vernier calipers and micrometers for the measuring and modelled all components as accurately as possible from their finished real life pieces. I will continue to add more detailed screenshots of individual components in the future.

The Minimoto bike itself is a Chinese made Lucky Seven with a CAG engine.  The engine features a barrel and head kit I made myself and a full circle crankshaft.  I also modified the expansion chamber and frame on the bike as well as making my own header pipe and carbon fibre muffler.  Unfortunately I don't get the time to ride my minimoto regularly anymore and my size is more suited to real sized bikes anyway.

Enjoy and please feel free to offer any comments.