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First Look! Durrani's New One-Piece Wheels
First Look! Durrani's New One-Piece Wheels
Dave Solo
Published by MCADXmag
04-08-2008
Featured Articles
Page 1

First Look! Durrani’s New One Piece Wheel

©Dave Solo 2008, MCADX Magazine Feel free to link this article, but please – no cutting and pasting.


It’s not yet time to settle bets on this issue, but the ultimate outcome is getting closer.


Sheryar Durrani’s work in progress (full details here) made a significant step forward when the first test batch of his new one-piece, magnesium wheels were successfully thixomolded on Friday, April 4th, 2008.

These are pictures of the pre-production front wheel, which will undergo rigorous testing in the next two weeks. It is not a prototype: it was produced in the exact manner that Durrani expects the final production wheels to be made after all testing, evaluation, and any necessary adjustments in design or process are completed. Only after wheels from multiple batches have passed all tests - conclusively and consistently - will they be made available for purchase.
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No hubs attached, but still very light
Durrani has been working ceaselessly on these one-piece, thixomolded wheels since abandoning his original multi-piece design, which proved too costly and difficult to produce. The new wheel is shown next to the original “Thixocore,” which was intended to serve as the structural basis for his original design. A rolled ring of extruded magnesium was to be welded and bonded to its narrow rim.
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The new one-piece rim is on the left. The Thixocore was part of a multi-piece solution that wasn't...
Interestingly, the new wheel weighs only four ounces more than the Thixocore. You can see that material has been removed from the hub area and some of the spoke structures, which were seen after testing to have been overbuilt. Model-specific hubs and cush drives made of magnesium will thread into the wheel centers.


The rear wheels are scheduled to be produced next week.
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I asked Durrani what the procedure would be to test the wheels:
<< <    Next Page: The testing procedures (Page 1 of 2)    >  >>
  #1  
By Unregistered on 04-09-2008, 12:08 AM
One Year Ago.....

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  #2  
By Repeater on 04-09-2008, 04:17 AM
Great article!

What price are the new wheels going to go for and is he going to offer the believers that got refunds the opertunity of getting the old price they ponied up in the begining?

So what these rings gonna cost?
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  #3  
By CBRVFR on 04-09-2008, 05:59 AM
For prospective buyers, I think that if there is anything to be learned from the last year, it can be summed up in three words: Wait and see.

This is progress, but not completion. Durrani has to get the front and both rear wheels (5 1/2" and 6") to pass all if those tests, which will take several weeks if everything goes well. As we have seen, sometimes it takes longer...

Once that happens, then I think that issues of pricing and delivery will be widely disseminated.
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  #4  
By SheepOfBlue on 04-09-2008, 06:38 AM
Good luck to him. Yep I will certainly wait and see. Though it would be good to see hard work and risk taking pay off even in the new age of socialism.
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  #5  
By Unregistered on 04-09-2008, 09:04 AM
Threaded hub info?

Interesting follow on article. I'm really looking forward to seeing how well the mold-fill analysis worked for the longer flow path of the rear. It looks like there might be some blush issues with the front, so it would follow that the rear might have more issues with both blushing and flow lines. Any info on what the new secondary finishing process will be?

Also would like to hear more detail about the threaded hub design, how it is preloaded and retained. And more interestingly, what are the testing parameters for this aspect of the wheel? Does the testing procedure realistically load this joint with the braking/drive torques that the wheels will see?

Kudos for the article series, and kudos to S.D. for sharing the information.
Keep it coming!

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  #6  
By CBRVFR on 04-09-2008, 09:51 AM
Quote:
Any info on what the new secondary finishing process will be?
I'll see what I can find out.

Quote:
Also would like to hear more detail about the threaded hub design, how it is preloaded and retained. And more interestingly, what are the testing parameters for this aspect of the wheel? Does the testing procedure realistically load this joint with the braking/drive torques that the wheels will see?
The threads are reversed on one side of each wheel. For the front, this means the braking force will always be tightening the hubs into the wheel, and on the rear, the right side will tighten in the direction of the braking force, while the left will tighten in the direction of acceleration - IF you put the wheel on in the right direction! Durrani intends to have those who purchase the wheel sign off electronically on this issue. I don't know how subsequent owners will be informed.

When the wheels are assembled, the hubs are tightened with 2000 foot-pounds of torque. His testing shows it takes more than 1600 foot pounds of torque to break them free. (I saw them test this. It didn't break free with any degree of abruptness, if that's a word.) They may also use a chemical thread lock. (this is a correction from my earlier statement.)

The TUV testing regimen refers to torsional tests, which I now understand to mean are repetitive starting and stopping from high speeds over those many, many cycles.
Last edited by CBRVFR; 04-10-2008 at 12:27 PM.
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  #7  
By ND4SPD on 04-09-2008, 02:36 PM
Can the hub potentially overtighten and strip like a normal nut/bolt can?
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  #8  
By CBRVFR on 04-09-2008, 02:51 PM
My understanding is that the braking and accelerating forces of the bike will come nowhere near developing the torque levels used to tighten the "mother of all bolts" to 2000 ft-pounds in the first place. The example I was given was an engine rated at 100 ft-lbs of torque at full throttle in first gear would develop perhaps 5 times that torque, due to the force multiplication of the gearing. The idea is that 500 is just a quarter of 2000, a safety factor of 400 percent.

I'm not an engineer, so if others want to challenge that, it would be interesting to see what the response would be.
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  #9  
By SheepOfBlue on 04-09-2008, 04:03 PM
I would think that tire grip would be a limiter on how much can be applied.
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  #10  
By Unregistered on 04-09-2008, 06:02 PM
Quote:
Originally Posted by CBRVFR View Post

When the wheels are assembled, the hubs are tightened with 2000 foot-pounds of torque. His testing shows it takes more than 1600 foot pounds of torque to break them free. (I saw them test this. It didn't break free with any degree of abruptness, if that's a word.) They no longer intend to use a chemical thread lock.
Interesting...was the FEA work done with that preload in place? The center hub section seems very wispy.
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  #11  
By CBRVFR on 04-09-2008, 08:12 PM
I'll have to ask that question directly - check back tomorrow mid-day.. if there are any follow-on questions, add them before then, OK?


I'll try to get some pictures of the hubs - they look pretty substantial.
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  #12  
By Unregistered on 04-09-2008, 08:21 PM
Quote:
Originally Posted by CBRVFR View Post
I'll have to ask that question directly - check back tomorrow mid-day.. if there are any follow-on questions, add them before then, OK?

I'll try to get some pictures of the hubs - they look pretty substantial.
I'm talking about the center section of the wheel itself...it seems a bit wispy for all it's doing, but perhaps they really optimized things while doing the FEA...
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  #13  
By CBRVFR on 04-10-2008, 12:25 PM
Here you go:

"Extensive engineering analysis was done on this product, including Finite Element Analysis (FEA). Preload was absolutely considered in this engineering analysis where required."

Durrani made two more points:
  • All engineering analysis is tempered until confirmed by real physical testing in the real world, such as is occurring right now, and
  • Optimization is the name of the game.
Also, to correct something I wrote above, Chemical bonding of the hub threads is still under consideration.

In answer to an earlier question regarding finishing, a ceramic chemical conversion coating and powder coating will be applied in the same way as intended in the original design. This is described in the Wheels Within Wheels articles.
Last edited by CBRVFR; 04-10-2008 at 07:42 PM.
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  #14  
By Jaeson on 04-21-2008, 11:22 PM
Challenge

Quote:
Originally Posted by CBRVFR View Post
My understanding is that the braking and accelerating forces of the bike will come nowhere near developing the torque levels used to tighten the "mother of all bolts" to 2000 ft-pounds in the first place. The example I was given was an engine rated at 100 ft-lbs of torque at full throttle in first gear would develop perhaps 5 times that torque, due to the force multiplication of the gearing. The idea is that 500 is just a quarter of 2000, a safety factor of 400 percent.

I'm not an engineer, so if others want to challenge that, it would be interesting to see what the response would be.
As it may seem that information is slightly incorrect. The amount of ft-lbs measured at the out surface of a tire is less than that measured near the core. I would only assume that a 400% safety factor is a bit generous.
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  #15  
By ND4SPD on 04-26-2008, 11:44 AM
Is there any word on the results of the test yet?
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  #16  
By SheepOfBlue on 04-26-2008, 02:29 PM
400% is a bit generous but not overly so. I would design at 200% for any critical part that can affect a life as a MINIMUM. 400% just sounds responsible.
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  #17  
By ND4SPD on 06-04-2008, 09:48 PM
Still no update?
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  #18  
By CBRVFR on 06-18-2008, 07:51 PM
Check back this weekend.
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  #19  
By Unregistered on 06-25-2008, 12:03 PM
Checked back on the weekend, no update.
Will check again this weekend as well.
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  #20  
By seamus on 07-01-2008, 11:16 PM
I got your update:

Herr Durrani made a visit to MCADX Days at Grattan todayand we got to put hands on rims. As I was walking to my garage, I saw this guy walking down the paddock with a bright green rim in his hand. As we got closer, I recognized him from a picture I had seen but before I could say hello, he says "Hold this for me" and tossed the rim towards me.

All I can say is HOLY F**K!!

I need a set for an 04 CBR1000RR and a 98 VFR. I'll wait, it definitely looks like it's going to be worth it.
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  #21  
By for1only on 07-02-2008, 05:04 PM
saw these at the track as well-I've taken heavier sh*ts than that rim-definately on my want list-hmm maybe for when I get that R-1?
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LinkBack to this Thread: http://www.motorcycleaddicts.org/outspoken/13147-first-look-durranis-new-one-piece-wheels.html
Posted By For Type Date
Durrani magnesium wheels? - Page 203 - 13x Forums This thread Refback 07-03-2008 10:24 AM
MotorcycleAddicts.org This thread Refback 05-02-2008 08:29 PM
First look at the Durrani One-Piece Wheels. : Suzuki GSX-R Motorcycle Forums: Gixxer.com This thread Refback 04-26-2008 06:52 AM
First look at the Durrani One-Piece Wheels. - Page 8 : Suzuki GSX-R Motorcycle Forums: Gixxer.com This thread Refback 04-18-2008 09:33 AM
VaporWare: Durani Wheels... the saga continues - DCSportbikes.net: Your DC Sportbike Information Portal This thread Refback 04-16-2008 02:35 PM
VaporWare: Durani Wheels... the saga continues - DCSportbikes.net: Your DC Sportbike Information Portal This thread Refback 04-16-2008 02:23 PM
VaporWare: Durani Wheels... the saga continues - DCSportbikes.net: Your DC Sportbike Information Portal This thread Refback 04-16-2008 02:22 PM
Durrani magnesium wheels? - Page 156 - 13x Forums This thread Refback 04-09-2008 03:27 PM
First look at the Durrani One-Piece Wheels. - 13x Forums This thread Refback 04-09-2008 11:55 AM
Nor Cal Riders - Rider Forums This thread Refback 04-09-2008 11:23 AM
Durrani magnesium wheels? - Page 156 - 13x Forums This thread Refback 04-09-2008 10:49 AM
Durrani magnesium wheels? - Page 156 - 13x Forums This thread Refback 04-09-2008 08:16 AM
First look at the Durrani One-Piece Wheels. - 13x Forums This thread Refback 04-09-2008 07:40 AM
First look at the Durrani One-Piece Wheels. : Suzuki GSX-R Motorcycle Forums: Gixxer.com This thread Refback 04-09-2008 02:56 AM
First look at the Durrani One-Piece Wheels. : Suzuki GSX-R Motorcycle Forums: Gixxer.com This thread Refback 04-09-2008 12:41 AM
Durrani magnesium wheels? - Page 156 - 13x Forums This thread Refback 04-09-2008 12:13 AM
Durrani magnesium wheels? - Page 156 - 13x Forums This thread Refback 04-09-2008 12:11 AM
First look at the Durrani One-Piece Wheels. : Suzuki GSX-R Motorcycle Forums: Gixxer.com This thread Refback 04-08-2008 11:52 PM
First look at the Durrani One-Piece Wheels. - 13x Forums This thread Refback 04-08-2008 11:36 PM
First look at the Durrani One-Piece Wheels. - 13x Forums This thread Refback 04-08-2008 11:35 PM

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