It just takes a picture

Broken an unobtanium part?
Fear not! Armed with a scanner and a rule, we may be able to solve that problem for you.

After a chain failure the already very brittle looking rear mudguard on a Yamaha TZ250 took quite the beating.
Missing a corner it was now looking very tatty and in need of replacing. Something that isn't super easy on a 40+ year old bike.
This was a great opportunity to try out a new technique where you get an image of the component , scale match it then make a copy in Fusion 360.
There are a number of potential advantages to working this way: For one, you will get an accurate copy of the component you are trying to recreate quickly but you will also have a basis to improve upon the design, depending on your taste.
As you can see on the image on the right there is a large chunk missing that chain side which some artistic licence is require but otherwise this is a simple flat plate with an added joggled section to allow for wheel clearance when the chain is adjusted with the wheel fully forward.

A few hours later and the printer was set off making use of some clear PETg. The original component is made of ABS. PET was an easy choice as it is non toxic and very durable even at high temperatures, with the proximity to the hot exhaust, this is important. It is available is a wide variety of colours, can be blended (with carbon fibre for example) for added strength and can be smoothed with asetone if the printed look is not for you.
We opted for a 20% infill with a 5 layer upper and lower surface which will be more than strong enough whilst also adding lightness, which we hear is a good thing.

5 hours later we had a first draft printed and fit up to a bike in the middle of rebuild.
It fits up great just requiring a few tweaks to allow for easier bolt alignment and a slightly larger radius to clear the swingarms chain guide. We even like the semi-transparent finish which the autumn sun is making the most of.
If you need a part recreating in 3D design, send us a message at HPE on Facebook whether you want the end product simply rendered, produced in plastic as above or send off for CNC machining/injection molding.
The Yamaha TZ250/350 mudguards will be available soon, check out our Facebook page for availability.


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