My Flux XL conversion with 1717 and center diff

Not your average Savage Hop ups. These are highly modified, with some home-made parts.

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marco73
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Re: My Flux XL conversion with 1717 and center diff

Post by marco73 » Mon May 07, 2012 7:03 pm

hello
in the central part of the front and rear axle which have mounted.
type and code thanks

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s2022
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Post by s2022 » Sun Sep 02, 2012 3:42 pm

Hello everyone, have been quite busy lately, finally had some time to tinker back on my project.

Well the previous design did work well but had some quirks of its own, and i never did manage the mechanical brakes. here is my second attempt to get things going.

Here is the design idea:

Image

preferred to rotate the brake pads to a vertical position and use aluminum arms to apply the pressure.
[color=blue]Regards
RCS2022[/color]
[color=blue][i][url=http://www.savage-central.com/modules.php?name=Forums&file=viewtopic&t=93732]Savage Flux XL; Mamba XL2; 1717; Custom CD; Mech Brakes[/url][/i][/color]

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s2022
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Post by s2022 » Sun Sep 02, 2012 4:00 pm

Here is a sequence of pics showing the CNC milling process, did not post all the pics, left them on the picassa album for any interested.

The right plate being milled:
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Left and rear plates milled, milled the internal cutouts and drilled the holes, then reclamped to mill the outer profile, this saves time realigning the mill or having to keep tabs or bridges and cut them later.
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Re clamped and outer profile milling
Image
[color=blue]Regards
RCS2022[/color]
[color=blue][i][url=http://www.savage-central.com/modules.php?name=Forums&file=viewtopic&t=93732]Savage Flux XL; Mamba XL2; 1717; Custom CD; Mech Brakes[/url][/i][/color]

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s2022
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Post by s2022 » Sun Sep 02, 2012 4:06 pm

While milling i left the bearing seat holes smaller, now internally boring the bearing seats:

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Test fit before removing from the mill face plate. all fine so far.
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The components of the Center diff support, the center piece is the motor mount plate; the motor gets screwed on it and it is supported to the front plate which is the one above it in the pic.
Had to do this t clear the brake disk.
Image
[color=blue]Regards
RCS2022[/color]
[color=blue][i][url=http://www.savage-central.com/modules.php?name=Forums&file=viewtopic&t=93732]Savage Flux XL; Mamba XL2; 1717; Custom CD; Mech Brakes[/url][/i][/color]

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FluxNZ
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Post by FluxNZ » Sun Sep 02, 2012 4:12 pm

Great work.

The design looks really solid 8)
Savage Flux HP - Mild Mods.
Savage Flux 5SC/5T - Custom built.
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s2022
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Post by s2022 » Sun Sep 02, 2012 4:19 pm

Drilling the holes in the front and rear plates, kept a bearing in place and clamped both plates on the vice to have a good alingment.

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Well now comes the problem part....

forgot to offset the tool bit while drilling the holes, if you look closely on the following pic in the bottom left corner, notice the right plate is extended lower than the left  :(:(:(:(

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More problems, while test fitting of the plates to the TVP's the measurements i did were messed up, the whole assembly had to be offset 2 mm , thats the reason for the additional holes laterally. the vertical holes are due to the later reason of forgetting to offset the tool bit.

Image
[color=blue]Regards
RCS2022[/color]
[color=blue][i][url=http://www.savage-central.com/modules.php?name=Forums&file=viewtopic&t=93732]Savage Flux XL; Mamba XL2; 1717; Custom CD; Mech Brakes[/url][/i][/color]

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s2022
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Post by s2022 » Sun Sep 02, 2012 4:20 pm

Hey thanks FluxNZ, been following your work also, just great!

read on, got stumbled upon some problems.....
[color=blue]Regards
RCS2022[/color]
[color=blue][i][url=http://www.savage-central.com/modules.php?name=Forums&file=viewtopic&t=93732]Savage Flux XL; Mamba XL2; 1717; Custom CD; Mech Brakes[/url][/i][/color]

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s2022
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Post by s2022 » Sun Sep 02, 2012 4:25 pm

Whats more worse than the above, the motor support plate also had the dimensions for mounting on the 1717 wrong. I just opened the files i had from the last conversion like 5 months old and started designing without rechecking and measuring again....

Thats the price you pay for being hasty. Note to self : MEASURE 3 TIMES AND CUT ONCE!

here is the second version of the motor plate, had some fun on CAD to get this design...

Image

I will go on with the Plates, to get a test run then cut new ones.
[color=blue]Regards
RCS2022[/color]
[color=blue][i][url=http://www.savage-central.com/modules.php?name=Forums&file=viewtopic&t=93732]Savage Flux XL; Mamba XL2; 1717; Custom CD; Mech Brakes[/url][/i][/color]

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LLkoolskillet
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Post by LLkoolskillet » Sun Sep 02, 2012 4:30 pm

Ah I find the old say'n messure twice cut once to be so true. When I made my CD setup I screwed up a few times and I always mess up hole allignments haha. I use my eyeball for measuring sometimes. Still tho I have to say killer job on the parts, they look professional, regardless of the fact they may not fit. My moto is if it doesnt fit make it! Sometimes its more work to remake them then to tweak the finished product.
[img]http://i1105.photobucket.com/albums/h358/LLkoolskillet2/skillet1.jpg[/img]

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FluxNZ
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Post by FluxNZ » Sun Sep 02, 2012 4:37 pm

Not easy custom designing and machining.

Can take a few goes to get it right but keep up the good work and it will be sweet :wink:
Savage Flux HP - Mild Mods.
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s2022
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Post by s2022 » Sun Sep 02, 2012 4:42 pm

Guys thanks for the comments and encouragement, making it work, had to modify lots of things on the spot.
[color=blue]Regards
RCS2022[/color]
[color=blue][i][url=http://www.savage-central.com/modules.php?name=Forums&file=viewtopic&t=93732]Savage Flux XL; Mamba XL2; 1717; Custom CD; Mech Brakes[/url][/i][/color]

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s2022
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Post by s2022 » Sun Sep 02, 2012 4:49 pm

This is the general view of how i am going on with the mechanical braking, the brake arm will have to be supported to a block support, then on to the right plate. a pin is needed to have the arm sway correctly and inline.


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Turning the brass pins for the arms, they will be supported in place by a set screw.

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The finished pin
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Image
[color=blue]Regards
RCS2022[/color]
[color=blue][i][url=http://www.savage-central.com/modules.php?name=Forums&file=viewtopic&t=93732]Savage Flux XL; Mamba XL2; 1717; Custom CD; Mech Brakes[/url][/i][/color]

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Post by s2022 » Sun Sep 02, 2012 4:51 pm

Was having fun on the CNC, my pinion remover....

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[color=blue]Regards
RCS2022[/color]
[color=blue][i][url=http://www.savage-central.com/modules.php?name=Forums&file=viewtopic&t=93732]Savage Flux XL; Mamba XL2; 1717; Custom CD; Mech Brakes[/url][/i][/color]

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Post by s2022 » Sun Sep 02, 2012 5:07 pm

Well after long hours of remodifying, finally the finished support with the mechanical braking working!

Image

And the Final test assembly pics. Wiring still needs to be sorted out. The mamba XL is huge, and with the Cap Pack not an easy fit in the Savage. Looks like a good place for now, the cap pack has no place but to have the wires bent as in the following pics.

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bottom view

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Image
[color=blue]Regards
RCS2022[/color]
[color=blue][i][url=http://www.savage-central.com/modules.php?name=Forums&file=viewtopic&t=93732]Savage Flux XL; Mamba XL2; 1717; Custom CD; Mech Brakes[/url][/i][/color]

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johny723
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Post by johny723 » Sun Sep 02, 2012 5:17 pm

incredible!

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s2022
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Post by s2022 » Sun Sep 02, 2012 5:18 pm

Did a test run on 5S everything looks fine, the brakes are awesome!
need to add a skid plate, as the last time i was bashing, i ran over a fist sized rock at full speed it dislocated the center diff assembly, sheared the TVP and a huge dent in the 6mm bottom plate and broke the plastic diff bearing support, the dogbones were also dislocated and bent, just have this pic forgot to take more pics. note the sheared TVP and the dent in the alum plate.

So skid plate then 6S WOT......

Image
[color=blue]Regards
RCS2022[/color]
[color=blue][i][url=http://www.savage-central.com/modules.php?name=Forums&file=viewtopic&t=93732]Savage Flux XL; Mamba XL2; 1717; Custom CD; Mech Brakes[/url][/i][/color]

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s2022
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Post by s2022 » Fri Sep 07, 2012 5:27 am

Got a video uploaded to Youtube, this is my first time posting and editing videos so bear with me.

[youtube]
[/youtube]
[color=blue]Regards
RCS2022[/color]
[color=blue][i][url=http://www.savage-central.com/modules.php?name=Forums&file=viewtopic&t=93732]Savage Flux XL; Mamba XL2; 1717; Custom CD; Mech Brakes[/url][/i][/color]

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FluxNZ
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Post by FluxNZ » Fri Sep 07, 2012 5:35 am

Runs really well. What weights you running in the diffs?
Savage Flux HP - Mild Mods.
Savage Flux 5SC/5T - Custom built.
HotBodies VE8.

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s2022
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Post by s2022 » Fri Sep 07, 2012 5:40 am

30k Front
10k Rear
i recall around 30k in the Center
Although the wheelies are a little more controlled, it still wheelies, still have to experiment on the center diff weight.
[color=blue]Regards
RCS2022[/color]
[color=blue][i][url=http://www.savage-central.com/modules.php?name=Forums&file=viewtopic&t=93732]Savage Flux XL; Mamba XL2; 1717; Custom CD; Mech Brakes[/url][/i][/color]

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s2022
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Post by s2022 » Fri Sep 07, 2012 5:52 am

more vids....


[youtube]
[/youtube]
[color=blue]Regards
RCS2022[/color]
[color=blue][i][url=http://www.savage-central.com/modules.php?name=Forums&file=viewtopic&t=93732]Savage Flux XL; Mamba XL2; 1717; Custom CD; Mech Brakes[/url][/i][/color]

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