Shift / Brake Levers

Posted by Will on Sep 18, 2012 in Machine Work

A pair of shift / brake levers for a custom Honda 350 race bike. Solidworks model showing the inside of the lever with the bore for the bearing and internal snap ring groove. I wanted to do a test interpolating the bearing bore. The first two attempts were unsuccessful due to the snap ring grove raising a burr on the inside of the bore. On the third attempt I roughed the bore, cut the snap ring grove, then finished the bore. It’s a nice tight sliding fit.

Fixturing these parts was challenging. I didn’t want to invest much time in complex fixturing given that these are prototypes and the design may change based on feedback from the racer or builder. I decided to face one side and rough out the shape (.01″ outside actual profile) so I could cut the chamfers on the outside. I’ll face off the small pads under the socket cap screws one at a time below the level of the part. Then I can flip the part and index it using the four holes drilled in the corners. All sides and bores will be finished from this side in addition to the bearing bore, snap ring groove and other features.

I’ll flip it and finish that up tomorrow.