83 cr500 one worthy of some love and tlc

Did you use a tool grinder machine to square edges. A machine shop tool for setting up - cutting tools for hardened steel ? Used to cut the hob teeth with these.

how did you index the engagement dogs to match sockets or slots ??

I have and also new 4 speed set to sell , haven't set a price. But you don't need that now. 40% of gears are new.

bang on you done your research too
1.5% shrinkage depending on alloy and liquid pressure during process

im not making gears just restoring lost metal and shaping beveled flats so not a hard task at all on husky gears hardening comes after machining and bedore final finish so cutting tools nothing exotic just carbide

new gears on a bike thats becoming hard find in decent condition deserve to be superfinished and set on ceramic bearings and raced in that order

mick83Husky...since then I have done a bit more down the rabbit hole reading about 3d printing and the questions I had seem to be answered in that:
: metal 3d printing in now a long and well known Thing!!...and the specs for the alum alloy seem to be at least 5010% BETTER than a usual alloy used on Brit Bikes, 356 T6...so THAT is f##%%%g amazing. I operate on the long slo time period unlike actual Progress!...lol.

I certainly need to know tons more, but the possibility of 3d printing, avoiding much of the machining sounds great!..an avoiding the costs of the foundry work, the cores, core boxes and all the stuff reqd to cast a simple barrel or cases seems very promising.

There are shops adverting for you to send them a file, they send you the parts. What a great world huh?

ok, now someone go and burst my bubble with a real world quote for 3D printed aluminum parts...size for one problem, BUT the printers!! are getting cheaper and cheaper and have room for some actual MC sized parts. 3d printers are now cheaper than a clapped out Bridgeport mill with obsolete tooling.

Well uncertain today were the industry is, but we have powderd metal gears in transmissions 40 years ago. Working in a gear factory as QC guy they were strong
but not as strong as the metal cut gears.

I could see this same product that was made under pressure, being made by a 3d printers. I have see made in front of me on a simple 3d printer for some sample gears
made. It was fascinating !! Also I have see a complete roller bearing made from scratch - I mean complete assembled piece. It was plastic , but could see how a special
powdered metal could be used. These were samples

Hear is the crazy thing all are made from the center of piece. So it builds bit by bit from the center of the ball bearings, center of races. And a piece appears as it grows from
the tiny spray jets. They are using human cells to make some tissue replacements now in the medical field.

It coming soon for smaller parts but to see big parts made - Go to the Space X site. The rocket makers. They are making complete large rocket engine parts for their engines by 3d printing today.

I saw some 3D printing examples in plastic about ten years ago. I had a bit of a hard time wrapping my mind around it at first. I saw a " Simple gearbox" sealed except for a couple holes for extracting the excess powder. Crank the input shaft & with gear reduction the output shaft would turn. Also saw what looked like a ball of string but in no places did the "string" touch itself. Was strange to look at the first time I checked it out. But the moving gearbox was cool. I know things have advanced a lot since my introduction to it.

INSPIRATION to get yours finished...

Scottm you have all the chain rollers and tensioner stuff that's a rare thing. For an 83 anyway.

That's been a problem from the outset , new YZ guides been installed.

Whats a good dent free 83 alu tank worth ?

pretty sure I have some of that 83 stuff PM me

Where

Are you based ?

Ive been racing all season so hadnt any spare time or money to get stuck into the husky but ive the motor rebuilt new bearings seals gaskets so wont be long now till i get testing this motor out

Very nice is that aftermarket decals on the tank?

I have this tank on ebay if anyone is interested to fund some other parts i need

in Nevada

oh I see you are in Ireland, I am in US

Ye a bit closer to sweden but that doesnt help haha