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 Freewheel selector DIY plans in the making

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T O P I C    R E V I E W
mellePosted - 06 Jun 2017 : 22:05:23
Some people have reported issues with freewheel selectors breaking or melting and the cast iron two stroke item being a suitable alternative. As those are pretty thin on the ground, I thought I'd draw the plastic one in CAD and put it on my website so folks can have a go 3D-printing it. Whilst I was at it, I thought that as a trained industrial designer (with a slightly side-tracked career) I could do better.*

On basis of the plastic selector, I've designed a part (not unlike the two stroke item) that can be made by any amateur with the right tools from a piece of 90x50x5mm flat stock (mild steel, aluminium, stainless, ...) and some 25mm bar. The flat piece can be shaped with hand tools or a laser or water jet cutter if you have access to one. The bar can be machined on a small lathe with a 4-jaw chuck (it needs an excentric hole), or even with a pillar drill if you work carefully. The bar can be a shrink or Loctite fit in the flat piece or it can be welded in place, depending on what tools and skills are available. I'll put a set of drawings and cutting files (for both manual and CNC cutting) up on my website when I've made and tested a prototype and paste a link here. If anyone else wants to have a go before I find the time to knock one up (could be a while...), let me know and I'll email you the files when they're ready.

As this is desktop engineering at the moment and I don't have a gearbox handy to verify, does anyone have a two stroke selector available that they can take a measurement off for me? I basically need to know the length of the piece of bar that goes into the gearbox (indicated in green in below sketch). The plastic selector is moulded, hence a bit more advanced in shape than needed in metal, but I need to know what design features I need to retain. A pic of the underside of the selector would help as well. Thanks in advance!

(top left: metal selector design/ top right: metal selector design individual parts/ bottom left: plastic V4 selector/ bottom right: the dimension I need in green)


*And apart from that, as Herbert Simon said: "Designing is a kind of mental window shopping. Purchases do not have to be made to get pleasure from it." (in: The Sciences of the Artificial).

www.saabv4.com
15   L A T E S T    R E P L I E S    (Newest First)
v4adminPosted - 30 Jun 2017 : 18:26:36
Nice one Melle
mellePosted - 30 Jun 2017 : 14:22:40


Fit is good, haven't got around to making the other part but confident this design works. I'll add the file to my site when I have time.

www.saabv4.com
green96v4Posted - 25 Jun 2017 : 20:43:25
excellent!!
mellePosted - 24 Jun 2017 : 21:23:34
Yes, I've liberated a set; will send it to Rhys when I'm back in the UK.

Also had two freewheel selectors water jet cut, pics later.

www.saabv4.com
green96v4Posted - 24 Jun 2017 : 11:40:41
Melle did you get anywhere with the brake caliper pins/springs?
mellePosted - 11 Jun 2017 : 13:53:51
Let me see what I can find, I'll keep you posted!

www.saabv4.com
green96v4Posted - 11 Jun 2017 : 13:43:43
thanks Melle

I have found these on the SaabKlubben site too, I'm happy to purchase them and have someone pattern them if needed, but we'd still be missing some elements for a full rebuild (and Melle's right about the top pin - looks like it doesn't have a separate part number in the parts catalogue)

https://svenskasaabklubben.nordicshops.com/product.html/fjader-bromsok-67-80?category_id=16
https://svenskasaabklubben.nordicshops.com/product.html/ledbult?category_id=16
mellePosted - 10 Jun 2017 : 19:05:21
I'm in my workshop next week, I'll see if I can find the parts.

www.saabv4.com
RhysNPosted - 10 Jun 2017 : 15:48:47
For that pin all we need is dimensions then. The bits that are a bit more complex, springs, clip would ideally be to hand.
I do need to have a proper look. Best option will be to get my purchase here and pull the bits out of my own car :) It will happen! Off to the US fr a couple of weeks, after that it comes home.
mellePosted - 10 Jun 2017 : 12:46:18
One of the pins is welded on and needs to be ground off.

www.saabv4.com
RhysNPosted - 10 Jun 2017 : 12:23:07
The person who needs to do the research on this returns from holiday today. I still need to find a sample set, good or bad, to work from.
green96v4Posted - 10 Jun 2017 : 10:54:55
Rhys - I would still be very interested in the brake pins, my resto is running beautifully now apart from the annoying thumping on the brake caliper!

quote:
Originally posted by RhysN
I was not meaning to go into parts production, just to facilitate anyone who wanted them cut. Melle I am sorry if I offended you. I have always passed things on at what they have cost me, or in many cases given them away.
Again apologies, obviously as a new immigrant to this country my efforts to help others are perceived as somewhat unusual, and seen as suspicious.
In cases like this, I have managed to locate people who can do these tasks, but doing a multiple is cheaper than one at a time. The same applied to the brake bits, and piston pins, I won't do other than find my own things any more, nor will I try to give bits to others who can't find them.
My conscience is now clear.

RhysNPosted - 10 Jun 2017 : 10:12:18
I am pleased I haven't upset you Melle. You are far too valuable a resource to annoy.
mellePosted - 09 Jun 2017 : 22:53:53
Great, thanks!

www.saabv4.com
WoodyPosted - 09 Jun 2017 : 22:35:38
The diagram appeared not as clear on my wife's ipad mini. Better on the larger screen of her laptop.
The height is 22.05 mm.

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