GL1000 Carb Button Design

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redglbx
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Re: GL1000 Carb Button Design

#31

Post by redglbx »

Imho, the nylon flat washer is the answer and then machine a small amount off of the guide in the cap to provide a flat surface that won’t cut into the nylon or felt washer, plus it could compensate for the added stack up of the piston so it fully pulls up out of the Venturi.

The washer would be the stop/bumper/buffer instead of the plastic button. If CF can get his “kits” together for $50 that would be a real bargain and the buttons would then just seal the chamber and be purely decorative.

On my oe 76 carbs I used copper plumbing caps very similar to the freeze plugs that S-Car Bob used, only copper. I spent a lot of time machining them to provide the correct amount of travel so the pistons actually stopped on the plumbing caps and not the pistons themselves.

I used a 2 part 3m epoxy similar to JB Weld that is gas resistant and they’ve been in there for around 20+ years, the downside is that you must be very, very careful not to slop the epoxy around in there and not cover the communication hole in the cap. I used a small bladed screwdriver to pack the epoxy back up under the lip in the cap that normally holds the buttons and used my finger to provide a bead around the outside between the plumbing cap and the carb cap.

If I was to do this today, I’d use a set of either OldFogey’s or CF’s buttons instead of the plumbing caps to keep it more oe looking and set them up to bumper against a set of nylon washers, back then 20yrs ago these were just “throwaway” bikes and I was more interested in just functioning not originality. Nobody was making replacement carb buttons at that time.

This has been a great discussion guy’s, thx !
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cfairweather
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Re: GL1000 Carb Button Design

#32

Post by cfairweather »

I now have a mold made out of aluminum, but it still needs a few minor changes. If I only had an injection system, but I will get one in time. I am going to use the same material that Pete used for his buttons, Delrin. Mine will be slightly smaller in diameter in order to make it easier for others to install them.
redglbx
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Re: GL1000 Carb Button Design

#33

Post by redglbx »

CF, 👍👍👍👍,, good job ! By the way Delrin is a good choice , you may want to try soaking one in gas to check for resistance. Shouldn’t be a problem but you never know these days. Just sayin !
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cfairweather
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Re: GL1000 Carb Button Design

#34

Post by cfairweather »

Thanks. I will test a pellet when I receive them in a few days. I am currently working on a very basic, maybe too basic, injection "machine" until I am able to buy a nice one. I will post some pictures of this thing once I get it all together. I am making it mostly out of junk that is in my garage. I did purchase the primary electronic components a few years ago, but never got around to using them. I am hopeful I will be able to fill my mold and make a nice button in a day or so, but I will not be surprised if it doesn't work out the first time. I really don't know much about injection molding, but I have never been afraid to try anything when it comes to tinkering.
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dontwantapickle
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Re: GL1000 Carb Button Design

#35

Post by dontwantapickle »

I've got a rack of 79 carbs that need buttons.
Keep us informed on your progress, I'll take 4.
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Re: GL1000 Carb Button Design

#36

Post by cfairweather »

I took a break from working on the buttons to help Old Fogey make a tool to bend the float mounts that he obtained from Pete's estate. I have learned a lot about injection molding and built a simple device. It is a piece of crap but my goal was to see if I could make one. Good news and bad news... Good news is I was able to inject one into my mold and it looks pretty good. The bad news is I determined my mold is a bad design and my machine is obviously a piece of junk. In order to do this right, I need a decent injection machine. I guess the important thing is I know I can make these because I did it but it will take a lot of money to do it right. For now, I will continue to print these with my 3D printer.
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Re: GL1000 Carb Button Design

#37

Post by Whiskerfish »

Looks pretty good!!
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Re: GL1000 Carb Button Design

#38

Post by rcmatt007 »

Very helpful as I have some carbs with missing caps
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Re: GL1000 Carb Button Design

#39

Post by BlueThunder »

Wasn't there a thread about using nickels as caps?
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rcmatt007
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Re: GL1000 Carb Button Design

#40

Post by rcmatt007 »

I think quarters
-Rodger-
all it takes for evil to prosper is the want of a few good men to do nothing-Edmund Burke
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978, BOTM June 2015 de-evolving this very moment viewtopic.php?f=30&t=65511
76 Ltd "cookies bike" ALMOST DONE
79 project, finished, FOR SALE
'86 1200 (Beth's)(FOR SALE) with motorvation sidecar (sidecar sold) , July 2017 BOTM
'17 HD Road king and 08 HD Heritage softail (Beth's) (FOR SALE). I guess you can say we have MBS
cfairweather
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Re: GL1000 Carb Button Design

#41

Post by cfairweather »

The problem with that idea is the flat bottom which will prohibit the slide from reaching the full open position.
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Re: GL1000 Carb Button Design

#42

Post by cfairweather »

I have decided to purchase a good quality injection molding machine and I am currently shopping for the right one. I will never sell enough of these buttons to pay for the investment, but I decided to do it anyway because I enjoy making things and I like supporting the GL1000 community. I will be making a high quality button kit for about $50.00 that will be reasonably easy to install. This kit will also include either nylon or felt washers for the slides. These will prevent the slides from slamming against the plastic and will fully open within 1mm. Stay tuned...
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Re: GL1000 Carb Button Design

#43

Post by rcmatt007 »

cfairweather wrote: Sat Jan 21, 2023 1:28 pm The problem with that idea is the flat bottom which will prohibit the slide from reaching the full open position.
I think they were raised by a washer. But I have slept since then
-Rodger-
all it takes for evil to prosper is the want of a few good men to do nothing-Edmund Burke
The question is not how much time do you have, it is what you do with the time that you have Gandalf
"One of the greatest dignities of humankind is that each successive generation is invested in the welfare of each new generation." Fred Rodgers
"it takes 10,000 hours to become an expert" ancient saying
78 constantly modified/customized since 1978, BOTM June 2015 de-evolving this very moment viewtopic.php?f=30&t=65511
76 Ltd "cookies bike" ALMOST DONE
79 project, finished, FOR SALE
'86 1200 (Beth's)(FOR SALE) with motorvation sidecar (sidecar sold) , July 2017 BOTM
'17 HD Road king and 08 HD Heritage softail (Beth's) (FOR SALE). I guess you can say we have MBS
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Re: GL1000 Carb Button Design

#44

Post by Sidecar Bob »

I found washers that would fit around the bumps and epoxied them on with nickles on top (I used 2002 Canadian nickles because it was the Queen's Golden Jubilee so the date was on the side with her head, not the side with the beaver like other years). They looked really good but it was NOT a permanent solution.
A few years later a forum member called keddano came up with the idea of using automotive freeze plugs and I expanded on that by adding plastic bumpers inside them and attaching the freeze plugs with small screws. 10 years later I consider that a permanent fix
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Re: GL1000 Carb Button Design

#45

Post by cfairweather »

Just a quick update on the button molding and injection project. I decided it would be easier for me to buy a high end 3D SLA resin printer system to make the molds instead of making them with aluminum. I bought a FormLabs Form 3+ along with the wash and cure systems. It was expensive (over $6,000.00 with the resin) but this is an incredible printer. The parts that come out of this printer are of the highest quality and Formlabs has the best resins for molds. I am using the 10K Rigid resin which can withstand 218C and lots of pressure. The plastic is extremely hard and strong. Today, I printed my first mold for the buttons and I am excited to try it out. First I have to make an aluminum case for it but I am getting closer. I also purchased an injection molding kit which I will put together in a few days.
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