GL1000 Carb Button Design

[Rat]

That’s a lot of carb buttons …

Gord

[Whiskerfish]

That’s a lot of carb buttons …

Gord

What he said!!

[Fred Camper]

Oh my, you are getting even more serious about this project. Wow, let us know when you are happy with the buttons.

[cfairweather]

I received my new FormLabs Form3 resin printer and I already created a new mold with it. I am using a very expensive, high quality resin that is very hard after it cures. It is almost like ceramic or glass so it should hold up pretty good. I am still doing some fine tuning on the mold, but I am very close. I got the plastic injection machine put together and it works great. I have already created some buttons but these still need some adjustments. I will probably be making two different buttons so people will have a choice. The first option will be a clear or nearly clear button and this is made out of PETG. I recommend this button for most people because it will be slightly smaller than the original to make it easy to install. The second option will be a button that will very similar to the original and it will be made out of acetal (POM). This is for people that are highly skilled like Old Fogey and want to do this as a service. Here are a couple I injected with acetal. Getting close...

20230213_185953.jpg (221.23 KiB) Viewed 318 times

[rcmatt007]

nice!

[5speed]

[cfairweather]

Today, I finished the mold that will be used to make the original replica button. Although it isn't a perfect replica, it is very close, and it should work just fine. It is made of Acetal which is an incredibly strong plastic. I think Honda used the same material. My button looks like the original and it even has the tiny ring on the underside. Zoom in on the below picture and you will see it. This tiny ring presses against a flat rubber sealing ring.

I cut a button in half so you can see the thickness of the plastic. Tomorrow, I will make about 100 of this type and then start working on the second design that I believe most people will prefer because it will be easier to install. Compare my button to the original.

ButtonReplicateStyle.jpg (225.14 KiB) Viewed 246 times

[Fred Camper]

wow, looks great. So you are saying these need to be pressed in from the underside? Your other offering will go in from the top?

[cfairweather]

They have to go in from the top.

[rcmatt007]

I have a set of 75 carbs with holes in the plastic. I will have to take that off and look at how that fits.... but these would make those carbs useable. now I just need a 75 engine

[cfairweather]

For testing purposes, if you will send me your caps and slides, I will install new buttons on them and you can report back to the forum on how you think they turned out. All you have to pay is shipping.

[rcmatt007]

will do

[redglbx]

Again,,,thanks for doing this CF !

[digger]

Yes Cedric, a big thank you for the time, money and expertise you are investing into this project, you are truly one of a kind and much appreciated

[cfairweather]

Thanks, I enjoy it and I have a very understanding wife.