mandag den 13. oktober 2014

In the following chapter shows updates that has been made along the way, some of them might be seen as updates and/or as improvement to the product.

after these updates the WAW performs like the high speed cruiser it is, with the best driving properties in the business...period. 
         
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  • Head light was refitted in the nose almost 25cm higher in the nose, carbon cloth was vacuum evaporated around a plastic tube, The original head light was refitted (Phillips Safe Ride 80lux) 

Even though the supporting of the nose cone was difficult it was done with styropor and duct tape. 


Funny thing when drilling in the nose cone you will find how rigid the kevlar material is. 
The mold was made in the nose cone piece itself




Recommendation:
If I should make again I would make the finished mold, complete and "glue" it in place afterwards.   
One side effect was that the pipe is also acting as a fresh air intake (around the head light), but intention was that a lexan glass should be fitted over the head light.

  • Additional in the enlarged hole from the previous light position a new air intake is to be installed.

Two carbon pipes was glued together and and a mold of the nose cone was made to get the correct form. I call it "the pig snout" 
"Pig snout valve" 
The idea is to have the two slots; one in each 30mm pipe that also each have a spring loaded piston, that is operated from inside the WAW, when the piston is pulled back the piston opens the slot and let in the air.  


  • A back fender is mounted as the long tail looks nice but collect a lot of dirt as it can pile up in the back, unfortunately the back wheel is a little more difficult to remove but all worth it!   






  • Rear wheel bearings worn out after 1200 km and a Sunn Riegel rear wheel is mounted together with a 2" Kojak from Schwalbe





Cracking?  
One hair line crack was found on top of the back. As at turn out it is only the top coat/paint that cracks and no fracture of the kevlar, as the other cracks where the paint did crack (Yes i´m so happy! :-) )  


"Hair line crack in the topcoat or paint but no cracks in the kevlar" 
After this find I decide to reinforce the nose cone where the cracks is found in the paint and 



the same is done to rear top of the top corner of the back fairing.


 
It comes out good and stiffen the structure perfect as planned  




  • Stoplight added: 

A SMD back light was added as brake light. 





  • Cracks in the back wall was monitored and no development was found, actually it seams like something went wrong during fabrication and I decided to repair it as well. It is ground down and filled with epoxy and fiber woven cloth. 





ready for paint

Finish result, not paint shop finish but is covered by the back end  



  • After a short while I dismissed the rear derailleur, in my opinion the Shimano Dura-ace road versions are just not strong enough in the spring, to tension the chain sufficient, so an SRAM XO was mounted and this improves the chain tension significantly, bad thing about this change is I had to dismount the bar-end shifter to a grip shifter type, this type is more difficult to opperate during riding with moist hands. so either gloves is mandatory on the long rides.    



"This is sugar stuff"



  • Chain line update: 

After several adjustments (Read: A LOT), the chain line seems to be running close to optimal.
The idlers has been adjusted up and down and guide tubes left in the WAW likewise adjusted. 
Actually I'm starting to like the chain line better in the XL model after the modifications, than in the ordinary WAW as the chain slides inside and on the bottom of the body.
Before I came to the conclusion of rebuilding the chain channel in the floor I was trying with five idlers 2 on the drive line and 3 on the return side but the last roller lifting the chain from the floor in the back was removed again after the rebuild (picture shows the 3 rear idlers before rebuild, 2 on the return line and 1 on the drive line) the rear two idlers was mounted further back as well.

Rear idlers arrangement prior to rebuild. 
 
as described earlier the "floor" was lowered in the chain channel, this was done with carbon and resin. The result doesn't look very nice on the picture (prior to sanding)but is actually smooth and extremely strong. The outcome is that the chain is not dragging over the floor as previous.
the chain cover is cut rough over the new floor shape. 



Bottom view:
       


Finish result. 



  • Battery update: 

The WAW is delivered with the 6 volt solution from Sigma IION XL, I quit like this very small battery. At first one extra was purchased, but more that 4 hours of use is optimistic to believe in. 
So a 12volt Flevo bike battery has been mounted



At the same time the switches are moved to the right steering handle in a small aluminium bracket, and the light switch is in a aluminium bracket on the front right fender, electrical horn is added (The red switch) as I have to often experienced, at high speed driving other bicycles can not hear the "bike pump" driven compressor horn mounted from fabricator.   



So when water now enters under the dashboard it doesn't run into the switches...that's is very nice to be able to keep the lights on in the rain :-)
The blue cable tie is retaining a small switch that fits in my palm and activates the brake light that is also mounted. 

New Dash board is mounted!





Winter project is to update the "spaghetti pit" of cords from in the right side of the WAW, but for now it is functional!  
        

  • After having ridden the WAW 184 that is a XL model I have observed how the body works and I will reinforce the area of the left longitudinal profile on the floor from where the front side of where the back idlers is retained. (There is like a line on the floor.) 

This left side profile is the longest piece of profile and seems like here maximum movement, not much but movement. 

This profile is now reinforced with carbon, and this have stiffen the structure as wished. (plastic not removed on the picture)    



 


  
Status:


  • The WAW184 has now been running approximate 2500km, 2149km is documented on the Garmin 810 
  • The WAW 184 is now able to run long distances, and is fully functional.
  • The WAW have normal traces of daily use under the rear of the aero tail and under the nose cone.  

The WAW is running with 


  • XTR spd pedals
  • Gearing 56_46_34 and 34_11 
  • Crank arm drilled to both 155mm og 170mm distance 

  • X0 sram derailleur chain line updated with terracycle pullys (4piece) 
  • Rebuild to 12volt flevo bike battery_ switchs moved to handles 
  • Sunrigel backwheel with 2"kojak
  • Brake light added, signals lights changed.