CarbonSmith Carbon Fiber Parts - Honda CBR500R Forum : CB500F and CB500X Forums
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post #1 of 14 (permalink) Old 06-11-2018, 01:07 PM Thread Starter
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CarbonSmith Carbon Fiber Parts

Hey everyone, I just wanted to let you all know that I am going to start making some prototype parts for the CBR500R out of 3D Printed Carbon Fiber. Yes, real continuous strain Carbon Fiber. I own my own business called CarbonSmith and we concentrate in custom prototype parts for pro race teams, but I want to start making some parts for the CBR500R now that it is legal in the MotoAmerica Junior Cup. Some of the items we will be making are fairing stays, subframes, clip ons, levers, rear sets, lever guards, crash protection, airboxes, velocity stacks, gas caps, etc. This isn't going to be an overnight thing, but for those of you interested in some parts feel free to send me a PM. Thanks!


www.carbon-smith.com
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post #2 of 14 (permalink) Old 06-11-2018, 02:49 PM
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When I was racing I also manufactured some carbon fibre parts. I still have a measurable amount of carbon mesh, some rotten epoxy, my trusty old vacuum pump and some of the moulds still around.
I've mainly done body parts case savers and cosmetic parts. tell me more about this carbon printing got so far I've only heard about carbon infused pla.
Once you settle with rhings I'll be interested in a pair of velocity stacks and possibly a lighter airbox than the oem boat anchor.
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post #3 of 14 (permalink) Old 06-11-2018, 03:17 PM Thread Starter
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Originally Posted by Oyabun View Post
When I was racing I also manufactured some carbon fibre parts. I still have a measurable amount of carbon mesh, some rotten epoxy, my trusty old vacuum pump and some of the moulds still around.
I've mainly done body parts case savers and cosmetic parts. tell me more about this carbon printing got so far I've only heard about carbon infused pla.
Once you settle with rhings I'll be interested in a pair of velocity stacks and possibly a lighter airbox than the oem boat anchor.

The printer that I use has two stages, both of which are made using Carbon Fiber. The first stage is a chopped carbon fiber filament, the second stage is a continuous carbon fiber strand encapsulated in the chopped carbon fiber filament. The printer prints layers of each in different angles, creating a 3D print with a carbon fiber weave encapsulated inside of it.


I have already made a model of a short velocity stack to print for my Superbike Build next year. I also want to make an adjustable one for testing. PM me if you want me to print you a set.
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post #4 of 14 (permalink) Old 06-11-2018, 04:52 PM
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Quote:
Originally Posted by MraRacer#934 View Post
The printer that I use has two stages, both of which are made using Carbon Fiber. The first stage is a chopped carbon fiber filament, the second stage is a continuous carbon fiber strand encapsulated in the chopped carbon fiber filament. The printer prints layers of each in different angles, creating a 3D print with a carbon fiber weave encapsulated inside of it.


I have already made a model of a short velocity stack to print for my Superbike Build next year. I also want to make an adjustable one for testing. PM me if you want me to print you a set.
Looks cool.

There was a company in Slovakia called Motomaxx, making velocity stacks dor rhe 500. They shown nice improvements on the dyno - but it seems to be compared to the very restrictive EU spec staxks which have 35-30% of their surface area blocked. Tothezenith triwd them, but could not show any measureable benefit on the dyno compared his non-restricted stacks.

I'm sure you're aware of this velocity stack design. The one you have included seems (might be optical only) parallel kike a tube. It can be great for a modular adjustable stack, but the shape probably could be improved further.
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post #5 of 14 (permalink) Old 06-12-2018, 04:51 AM
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As I think of it a lighter weight rear caliper bracket would be also a worthy upgrade and quite a change in unsprung weight. Probably would not get as hot as the front brake either.

Also depending on strength a two part lightweight rear chain sprocket could be cool. Thinking of a two part construction similart to the supersprox stealth sprockets which have a high wear resistance outer part, and a lightweight inner section.

Also I dunno where are you compared to the weight limit of your class, and how big items can be printed on your machine but a lightweight instrument cluster holder and a rear subframe could help quite a lot competing those light ninja 400s and R3s.
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post #6 of 14 (permalink) Old 01-08-2019, 05:53 PM Thread Starter
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Originally Posted by Oyabun View Post
As I think of it a lighter weight rear caliper bracket would be also a worthy upgrade and quite a change in unsprung weight. Probably would not get as hot as the front brake either.

Also depending on strength a two part lightweight rear chain sprocket could be cool. Thinking of a two part construction similart to the supersprox stealth sprockets which have a high wear resistance outer part, and a lightweight inner section.

Also I dunno where are you compared to the weight limit of your class, and how big items can be printed on your machine but a lightweight instrument cluster holder and a rear subframe could help quite a lot competing those light ninja 400s and R3s.


I am working on a carbon fiber subframe, but it would be built only for track day use.

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post #7 of 14 (permalink) Old 02-27-2019, 09:26 PM Thread Starter
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Well the first version of the stacks are off to the dyno for testing.

These are 45mm tall with a 10% taper.

Will post results after we get them back.
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post #8 of 14 (permalink) Old 04-15-2019, 07:04 PM Thread Starter
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We are still working on final figures for a stock engine, but here is a comparison chart of stock stacks and K&N intake vs. CarbonSmith Stacks and CarbonSmith MA Spec Intake filter on a stage 2 engine. We found about 4% power increase at the top end and constant power gains across the entire curve.
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optimizer and Resolute like this.

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post #9 of 14 (permalink) Old 04-15-2019, 11:48 PM
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55 rwhp. Nice.
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post #10 of 14 (permalink) Old 04-16-2019, 11:04 AM Thread Starter
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55 rwhp. Nice.
That dyno reads about 10% high, so probably 49-50 on most other dynos.

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