TRX Update

The TRX project has crossed an important milestone - switchgear. I’ve got a working start, kill switch, hi/low beam, horn and turn signals. Only took a couple of weeks, sooner if I’d abandoned the KnS switchgear Instead, I’ve 3D printed a housing for individual momentary and latching pushbuttons, and the turn signals switch is looted from some KTM type switchgear. Wiring took a weekend - normally I would avoid modifying the bikes wiring harness, but with the switches used and 3D printed housing I had to de-pin the standard harness connectors and re-pin them into individual connectors. It’s a mod that can be easily returned to factory though, so that’s a plus.

I did wire in an oil pressure switch and oil pressure light, but I think the pressure switch is defective. Another one is on order. In the meantime I changed the bikes oil and filter - there’s a heck of a lot of oil in these things.

Allegedly, I rode the bike up and down my street a couple of times, just to free things up a little. I’m still getting used to the tall first gear and heavy clutch - low-speed work in my yard is a challenge. Once the clutch is out and the bikes trucks along pretty quickly (allegedly).

Paint for the TRX is the next hurdle - just the rear tail section needing paint and decals. I was originally going to use the top fairing as the paint sample but found a matching front mudguard on eBay for a good price and this will be the paint match. The screen is an aftermarket unit (Dreamscreenuk) and it needed some small Dremel mods to fit. Nothing major. Not sure how I feel about half fairings… looks like the bike has been crashed already.

Louise loves riding bikes but is struggling with the current Queensland heat and we’ve been using the car more than the bike this last week. However, her claim to my SWM is locked in, and I’ll start returning the SWM back to “two-handed” soon and have her learn to use the clutch. Clutch first, moving next. I did buy Louise a Sena Prism Tube camera for her helmet - the footage is good and the audio is better than expected. I’ll upload something to my youtube channel soon.

The arm, if I find the energy, will be running another small but critical update - I’ll be replacing some key components with 3D printed parts. This is the mechanism in the arm that actuates the FOX shock, currently from anodised 6061, to be replaced by 3D printed carbon-impregnated nylon. The 3D printed parts, in this material, are half the weight and two thirds the cost and considering the loads in the mechanism should be more than adequate.

The 3D printed switch housing. Printed in ABS now, but an SLS printed nylon part will replace it soon.

Louise coping with the heat at Yakapari Organic & Natural Store - our favourite stop for a coffee and snack.

FOX Shock is back

The FOX Shock is back in the arm. No test ride yet, but everything appears great so far. in the static tests Big thanks to the team at Mountain Bike Suspension Centre for getting the shock back so quickly.

I’m still to replace the centre components of the arm. These new parts add the revised accessory mounting, fold-out hook/clip and revised internal lever. Replacing those parts will be a bit of work, essentially a complete teardown.

Louise and I took the bike out this weekend, lots of fun and a lot of miles clocked up. The Oxford pillion grip thing is getting a little easier to manage… not much though. I also added a rack/pillion rest to the Enfield… not something I wanted to do to the bike, but needed to feel safer with Louise on the back.

The DnM shock is out.

Zip tie shock compressor.

Check pressure.

Done!

The busted shim pack = cause of the failure.

The weekend on the bike with my copilot.

Something to stop the midget falling off.

Arm update and Pillion Bits

Small update to the arm, but a more significant update coming just as soon as parts arrive. I’ve added the cosmetic guards to the sides of the arm.

I have a new centre section, doing away with the snap-fit connection instead using 4 x M5 threaded holes. I’ve also added a flip-down helmet hook to the arm. I’ll install this once I have some revised parts for the internals.

I had some spare coins laying around and thought I’d replace two key working components with 3D printed carbon fibre. Pure experimentation, it may not work but the cost of the 3D Printed CF is about 2/3 that of CNC 6061. Its worth a look.

I’m also kicking around an almost 80% 3D printed arm. Maybe not from CF but a mix of CF and polycarbonate.

In other news I bought one of these damn things for Louise

What. A fekin. Nightmare. I’m pretty sure I could have four arms and this would still be a PITA to get on. After about an hour of trying to get it on, I THINK I may have a technique worked out. Velcro is both my favourite thing, but also my worst enemy. That and I just don’t think Oxford did this as well as it could have been done.

Rage inducing nightmare girdle.

Outer covers for the arm.

Camping and Copilots

First up, my beautiful brave girl now rides with me! I’m a very proud Dad. We started small, a lap or two of the yard, then up and down our street and before we knew it we were in the city riding in traffic. In one afternoon. Here she is.

Jake and I rode the bikes to Notch Point for a camping trip. My first ride, one-armed, off-road. Probably should have used any other bike than my Royal Enfield, but it is what it is. The ride and the camp was a load of fun, and we have more planned.

I got to meet a few cool people out at Notch Point too, got a few pointers for future off-road rides. The current plan is to ride into the middle of Australia, so any and all positive advice/input is appreciated. The ride on video

The arm had some more tweaks, adjusted a few things for a more natural resting position and some cosmetics additions. I ditched the snap fitting and instead added a folding hook and some threaded holes for future addons. The FOX shock has not returned from its service as yet, but I’ve been lowering the pressure in the DnM shock gradually to find a happy medium. I’ve also had some of the internal parts 3D printed in the carbon fibre as a test. I’m impressed with the strength of this material and is roughly 60% of the cost of having parts machined from 6061 - shorter lead times also. If the trial goes well I believe I could replace a bulk of the arms aluminium components, reducing cost and weight further. There are critical parts that will always remain machined parts though… not sure I’d roll the dice on the connection between the arm and the hand being 3D printed.

Subcontract work is on the go slow. I may have burned myself out over the last six months. I have a habit of saying that, and saying I’ll have fun with all the free time… but, I can’t say no to subcontract work when it comes my way.

No updates on the TRX as I haven’t been near the bike in a month or so now. Family issues around differences of opinion regarding the current state of the world and the “illness” vs’ the “solution”. This in itself is a heated debate for sure, but it appears the division of society is working out well for those who benefit from it.

My new copilot.

Arrived at camp.

Camp deployed.

The view from the tent.

Dinner; beer, meat, potatoes and onions.

Breakfast, despite not looking the best it was pretty good.

Render of the arm - added some cosmetic covers.

The evolution of the motorbike arm.

Back in the Groove, TRX Stuff and a revised arm

Ah, so I’m still no good at regular updates, but I’m back designing HV equipment with Ampcontol Pty Ltd - its like I never left.

In other news, the TRX project is progressed to the point that the one-armed mods have started.

Louise and I are on a fitness kick as it turns out working 60+ hours a week in front of a computer is good for the bank balance but bad for your health.

I’m back designing HV equipment - Love it!

Me running after Louise on her skateboard in an effort to shake me desk jockey body.

TRX Clutch switch mod - no room for clutch switches on the lever now its has been relocated to under the front brake lever. So, I’ve repurposed a rear brake light switch on the frame.

The rear brake light switch acting as a clutch switch. Ignore the shonky spring mod, this will be cleaned up once everything is dialed in.

TRX front brake light switch mod - again, not enough room between the levers for a brake light switch. So, I’ve added a Brembo pressure activated switch. Note, the TRX has an R6 front brake upgrade and braided lines - good front brakes are important.

I’ll tidy this up as I’m mounting the new controls to the handlebar.

This bike has been a fantastic bike. Though, I’ve gone from riding it every day to once a fortnight now I’m a fulltime Dad.

The new arm - not a complete redesign, but I’ve moved things around to get the FOX shock out of the way somewhat.

The most notable change though is the use of 3D printed components - there are much less machined parts with this arm, only the critical chassis and operating components remain as machined 6061. This was to keep costs down both in initial design and future updates. A byproduct of the 3D printed parts is the 500g reduction in weight.

Take breaks.

Long overdue update

I’ve been busy; new project bike, back to doing subcontract work, riding bikes and family.

Also, I’m coming toward the end of a short term contract working with an industrial robot - programming/operating. Not going to lie, I’m pretty keen to get back to strictly mechanical design. Programming can be fun, and frustrating at the same time.

Small updates to the arm, swapping the DnM shock out for the FOX unit improved feedback, so I’m reworking the arm so the FOX mounts with the reservoir up inside the forearm. In a few weeks I should have a new hand design fabricated; simplifying the mechanism and (hopefully) improving the quick release.

The new project bike is a Yamaha TRX 850, 1998 - the same year I lost my arm. The plan is to get it back to “stock” and ride it for a while and see how it goes. I haven’t even test ridden the bike yet, but I have a feeling it’ll work out. Everything on the bike that helps it turn or steer has been replaced or overhauled - paid for by all the additional subcontract work…. I should be working right now.

I’m a little unsure where I’ll be in July, I have a few options for employment, but hopefully back to drawing pictures and getting square pegs into round holes. Hopefully, maybe, dial the subcontract work back and ride more.

The project bike, as delivered.

The work begins.

The arm is a tight fit.

Planning required; getting the arm to fit and the controls to work - not a lot of handlebar room.

Finding the right clutch lever turned out to be a challenge.

Just some of the new stuff going on.

I’ll be using the KnS switchgear for the TRX

FOX shock installed - high and low speed settings are a game changer.

Cosmetic cover.

Out with Jake and my Dad

Robot Studio / RAPID programming.

The robot.

Crab Bait - the cat

Book Thursday with my brave girl (every 2nd Thursday she gets to buy a new book… or three).

Take it easy everybody.

Exciting Times Ahead

ABB Robot Studio - my new learning adventure as I move from Ricbuilt to another company running automated equipment. I’ll announce where I’m going once I’m there, but I’ve worked with these guys for years and they a good bunch.

Other than that its the usual; work, bikes and family. A lot of group rides and time on the bikes with Jake.

Height adjustable access, using a hand winch… I’ll upload a completed photo once I have one.

Me, my Dad and Jake

Jake and I at a recent charity Toy Run

Jake taking the SWM for a spin.

Me taking the SWM around Sarina Range

Me pushing people down Sarina Range on the Royal Enfield.

Wrist watch?

The girl and the cat.

Louise and I made a car…. it was as hilarious to make together as it is hideous.

Robot Studio - I kinda like it.

Bit of an update

My life is made up of a few activities; work, riding bikes and hanging out with my family. Sometimes, if I’m really lucky I sleep.

The last few weeks have been hectic, a lot of work on, but I’ve tempered that with a few long bikes rides with my Dad and my son, teaching Louise to use Inventor and trying to keep up with my other son playing computer games (computer games arent my strong point).

As for what's going on at work - its been a whole lot of square-peg-round-hole jobs. in rapid succession. Some site work measuring up components and some cool stuff 3D scanning car parts.

I did 3D print a socket to help with my physio. This is part of the long journey that is building my own robotic arm; determining my range of movement, locating and learning to use the remaining nerves, and, building strength in my shoulder. This 3D print was from ABS and my first attempt at annealing printed parts…. there were failures.. but, I got there in the end. Can’t tell if that’s good or bad yet, as I push the limits of my short arm I encounter new and unfun pain. Fortunately, any pain is shortlived and I know what causes it. The 3D printed socket fits my short arm, has a connection for the gym equipment and laces to tie it to my out of shape body. It works.

I’d like to think I ride bikes better in the real world than I do in computer games.

Louise and the haircut

This was one of those big Dad milestones. My brave girl said goodbye to her long hair a couple of weeks ago, donating it to Variety the Children’s Charity. I’m really proud of her, and happy to see her thinking of others. Big thanks to Avaia Hair for letting me be a helicopter parent throughout the haircut. Louise handled the whole thing better than me.

Very proud Dad. Love you bub.

Enfield gets new Tyres

It took a while, about three weeks, but the Enfield is back on the road with new Pirelli Sports Demon tyres. Feels good. Still scrubbing them in, but so far they feel great - 33psi front and 40psi rear. Was originally looking to run Dunlop GT601’s but no ETA on those and had to switch to the Pirelli’s. Big thanks to Mackay Kawasaki for fitting the tyres.

I also fitted the fork gators and dropped the forks 10mm in their clamps. Finally, the single-seat arrived and was fitted.

Louise was the assistant grease monkey on this job.

SWM gets red

A change is as good as a holiday… or a new bike, right? I found an SWM fuel tank on eBay for $100 and couldn’t resist. I like both styles of fuel tank - the geometric and the more traditional shaped tanks offered by SWM - so jumped at the opportunity. Fuel tank - $100… new fuel pump, fuel sender and associated parts… too much, but still worth it.

The general public seems to like it to, a lot of positive comments and interest from random people. However, despite it now being red, the bike is not any faster. Myth busted I suppose.

Diesel Smart Turbo work

Occasionally, I get to do something a little different; 3D Scan a few parts to make a square peg fit a round hole. There’s another part to this, and I’m to make them work together. I canjt gve too much away, but the end product will appear over at Diesel Smart.

Road Trip

Photos from my recent road trip, home to Cairns and back over four days. Just a shade over 2000 kilometers and my first long distance road since my accident.

A great experience, loved the riding and the people I met along the way… and the beer, and the food.

The bike was perfect, no issues and great fuel economy despite the undersized fuel tank. I did the three ranges while up that way and again, the bike was fantastic - really enjoyed the corners.

50/50 Photos

Photos of the day. Took a quick ride out to the corner where I crashed way back on the 8th August 1998.

2020 is my 50/50 year

This year I will have spent 50% of my life with 50% of my arms, which will make celebrating my “Didn’t die day” extra special. The exact celebration is still up in the air, but I had my mate Robbie over at One Armed Graphics to hook me up with some 50/50 trophies. We should see those soon.

I’m not too focused on the 50/50 thing this year, more on rewarding myself for the last three years solid of subcontract work. I did some big hours in that time, got a little too close to adversely affecting my health and, worst of all, not spending enough time with Louise. What did I get out of it? Well, cash money sure and a wealth of experience in mechanical design, but I’m stuck on the lesson of finding the right work/life balance.

I should probably renovate my house….

NEW BIKE!

So I have a new bike - Royal Enfield GT650. It’s a great machine (so far), I’m still running it in, and it only has 475km on the clock, but I have a big ride planned for this weekend. The team at Norside Motorcycles completed the first service; top-notch work.

The bike was purchased from Wurth’s Rockamptpn, great guys 10/10 would buy a bike from them again. I rode the SWM from Mackay to Rockhampton, and back, to collect the bike, with the help of a beautiful Lady friend, my offsider Louise and her little friend. Absolutely no need to ride down and back, I just wanted to.

With the bike back safely, I worked through that night to finish the modifications required so I could ride the bike. No issues aside from the difference in wiring, meaning I couldn’t use the KTM switch housing for start/kill. Instead, I printed my own housing and used some generic switches. Not having a long enough clutch lever are I used the SWM’s original clutch lever and perch, which worked with the Roya Enfield’s clutch cable. In my research on the Royal Enfield, I had hoped to retain the factory RH side switchgear by installing the same indicator switch assembly I use with the SWM, but had to replace the factory unit with the same switchgear assembly I’m currently using on the SWM.

Future mod’s for the Enfield? Some of them are already on their way (sump guard, fork gators, fly screen and engine crash bars) but some louder pipes would be nice.

Motorcycle Controls - Update

I’ve been on the road for about a month now, new arm and dialling it in slowly as I build strength in my short arm. Along the way, I’ve made a few adjustments to the controls and the arm.

The arm now has a lower lever ratio / greater range of movement as well as a change in its resting position. I’ve gone from a resting position of 2 degrees at the elbow to 20 degrees, with a total range of movement of 85 degrees. The lower lever ratio means an initial increase in the shock absorbers air pressure, but I’ve since dropped that back to 30psi compression and maybe 10psi rebound. Still trying to find a sweet spot here between being able to easily move the elbow and having it return quickly to feel natural.

The controls have been updated by removing the Spirit Beast two-button housing and replacing it with a KTM style switch assembly. The KTM switch assembly is mounted to the underside of the RH switchgear assembly by way of an adapter plate. As with the killswitch being a Hi/Lo beam switch the momentary KTM kill switch required a relay to operate properly on the Gran Milano.

I was having an issue with the additional headlight relay failing but added rubber mount between the relay and the frame of the bike.

New control layout with the KTM switch assembly.

Headlight relay, mounted to frame with vibration mount.

Kill switch relay; the KTM kill switch is a normally open momentary switch, where the SWM needs an normally closed latching switch.

The new arm, the bike and yours truly.

Jacket sleeve sorted. The DriRider Mx Rally Cros Pro 3 has removable sleeves, which was fine for a while. I’ve since had the LH sleeve shortened professionally and it looks a lot better.

Motorcycle Arm Project - Complete

Well, 90% complete. I have redesigned the arm, completed my Qride Pre-learner course and I am on the road. The remaining 10% comes in three months when I have a shot at my RE license.

The new arm allows for a greater range of movement and has a more natural feel to it; length, hand position on the bike and the elbow can now articulate nearly 90 degrees without much effort. The wrist roll mechanism changed also, making it much smoother to operate, and I can adjust the pressure here now. Because the elbow mechanism has far greater leverage than my previous design, I’m using the DnM shock. The DnM shock has a much heavier spring rate than the previous arms Fox unit and doesn’t seem to require any revalving or tuning. I will try the Fox shock in the new arm later but have a feeling that, if the revalved shock does have advantages over the DnM, I’ll need to find a more compact Fox unit

The quick-release components were updated along the way, and this system is working great too, not just in operation but in allowing changes to hand position easy. In all of my original testing, I did run two o0rings between the hand and the two locating clamps, but in my next test ride, I’ll be running without those. If I’m not happy with that feel I may make the locating clamps from another material.

Photos and video below, after I give credit where credit is due. I’ve had a bunch of people help me along the way, either with building the arm, getting licensed and helping me cut through red tape. Let’s get started;

DJ Design and Engineering - This guy has been with me from the start, not just manufacturing the arms from the drawings/models I send him but also suggesting tweaks that improve the design and/or manufacturing.

Learn2ride Qride Mackay - Don’t underestimate the benefit of good rider training. I went into my Qride thinking I had it in the bag, there wasn’t much I needed to know or learn, one arm or not. Not true as it turns out. I had been practising, to develop my strength to use the arm and operate the bike/controls etc. And, I don’t think I’m that shabby. But, over two days I watched as Brett Hoskin took a group of us through far more than I’d prepared for. Not only that, it was a load of fun and that helped make everything we’d been taught stick. If you’re in Mackay Brett Hoskin is the guy to see for the Qride component of your motorcycle license.

CCW Vehicle Approvals - the red tape cutter Gav’ Cass. I’ve been an amputee for over 20 years and the only place I hate dealing with now is Queensland TMR if only because I have to keep providing evidence I only have one arm. QLD TMR really grind my gears, and I needed to have the modifications to the bike approved by these guys. Gav’ sorted it, no stress at my end… but, yeah, I still needed to provide evidence of having one arm.

Amy Gutterson - My occupational Therapist, who probably freaks out when I call, but who loves a challenge (me). Amy helped me with driving a manual car and was there for the motorcycle chapter. My only challenge now is choosing another vehicle license I’ll need her help with again…. light plane, heavy rigid or helicopter?

My Dad - This guy helped me get back on a motorcycle even after watching me lose an arm in a motorcycle accident. I can’t say much other than that. Along this journey we have spent many hours in the shed, working on the bike and the arm, and speculating on all aspects of motorcycling and life past present and future.

Qride - with the old arm.

Honda Goldwing - stereo upgrade

I’ve been tasked with modeling a housing that replaces the Honda Goldwings original stereo with a different unit. Watch for updates.

Controls updated

All controls wired up and functioning - VIDEO

Current state of the bars.