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The World is not round!! Homemade Square Cages

#1 2016-01-16 4:16pm

troynlori
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The World is not round!! Homemade Square Cages

Finally found some time to tool around with this and made myself some replacement cages.  This was actually an experiment to see if I could bend 90's as I may make a batch of squares.  I tested A) 5052 0.090" thick, B) 5052 0.125 thick, C) 6061 0.090" thick.  The results are positive for A) & C), however, 0.125 thick proved brutal, just brutal to bend.

So, first thing you do...make some measurements of a cage or body or both...  You may find you have to flatten a cage, as I did with my Suntour shaped cages:
https://s3.amazonaws.com/uploads.bmxmuseum.com/user-images/37108/dscn4208569ac9ceef.jpg
Take a caliper and measure away. 

Make yourself a drawing.  Here's an example of one I made (just a corner):
https://s3.amazonaws.com/uploads.bmxmuseum.com/user-images/37108/drawing2569ad5c261.jpg

For the home version, get some material:
http://www.onlinemetals.com/merchant.cf … top_cat=60
https://s3.amazonaws.com/uploads.bmxmuseum.com/user-images/37108/dsci2505569ad64b3f.jpg
Made a pencil drawing above...need to do better for next run.

Drawing your cut points, etc on the pieces.  There is a wide piece of material there for a reason - there is a strategy for making a pair in there:
https://s3.amazonaws.com/uploads.bmxmuseum.com/user-images/37108/dsci2784569ad6fc00.jpg

Drill press:
https://s3.amazonaws.com/uploads.bmxmuseum.com/user-images/37108/dsci2788569ad7506e.jpg

Clean:
https://s3.amazonaws.com/uploads.bmxmuseum.com/user-images/37108/dsci2791569ad76fa0.jpg

Use Dremel to separate the halves and to cut the outer edges.  I purposefully made the overall dimension wider than needed so I wasn't drilling holes on an edge:
https://s3.amazonaws.com/uploads.bmxmuseum.com/user-images/37108/dsci2794569ad7b303.jpg

Sand:
https://s3.amazonaws.com/uploads.bmxmuseum.com/user-images/37108/dsci2780-2569ad818c7.jpg

Clean.  There will be dust everywhere (consider dust masks and your area.  Also take care with metal dust hazards):
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2789%202_zpscdyono8b.jpg

Make a form:
http://i967.photobucket.com/albums/ae154/troynlori/cages/Form_zpsfwbtskur.jpg
Make sure you account for snap back!  You have to make bends further than necessary.  A cage should grab a pedal body...not have to be pulled down to it.

Using super human strength, shape the cages:
http://i967.photobucket.com/albums/ae154/troynlori/Patty.jpg
I tell you, it's all right there in that picture.  You generally should not need a hammer.  However, I didn't have enough to grip the short ends to make a 90 and for the first time in shaping, I used a hammer.  However, this is normally forbidden.

Marvel @ your new wonder:
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2794%202_zpsfaflowhw.jpg
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2795%202_zpsvvw7csm7.jpg
6061 turned out nice:
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2796%202_zpsqebenvbo.jpg
0.125 not very friendly:
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2797_zpsr1yc06ik.jpg
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2799_zpskipvvkkz.jpg

Sand again.  Forming process will mess up the finish:
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2803_zpsgaaaegaf.jpg

Find a horse that needs new shoes:
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2807_zps9doq4sq2.jpg
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2809_zpsd27b2v1a.jpg
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2810_zpstdk2b3lm.jpg
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2813_zpspx8tbrdh.jpg
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2816_zpssugnrvsq.jpg
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2817_zpskypwf8wf.jpg
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2818_zpsrhyemrux.jpg
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2819_zpsl6xsmjw2.jpg
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2825_zpsbrjtgypr.jpg
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2827_zps6fvqcick.jpg
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2834_zpstplzdthm.jpg

I don't have the sharp 90 of a JP pedal:
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI2834_zpstplzdthm.jpg

From here you can polish.  I use Metall aluminum aircraft polish, white scotchbrite pads and a mouse sander with the pad attached to it.  You need a long time...
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCN5879.jpg

Or you can go for a nice anodize:
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI0496.jpg
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI0388.jpg
http://i967.photobucket.com/albums/ae154/troynlori/cages/DSCI0381.jpg

I use this guy with positive results:
http://www.mcnicholsanodizing.com/

For proper cutting, you have to go find a guy with a laser or a water jet.  My guy uses a laser.

Last edited by troynlori (2016-01-16 4:28pm)


Hi.

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#2 2016-01-16 5:12pm

blue78
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Re: The World is not round!! Homemade Square Cages

Awesome!!  Great work!

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#3 2016-01-16 5:45pm

wfc09
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Re: The World is not round!! Homemade Square Cages

I see what you did there......Critical thinker ........Its PLAIN as the nose on your face wink.

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#4 2016-01-16 5:55pm

bmxpro2
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Re: The World is not round!! Homemade Square Cages

X


Boosted civic life.

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#5 2016-01-16 10:48pm

Dee
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Re: The World is not round!! Homemade Square Cages

Nicely done.

You could try leaving the short ends a bit longer to make it easier to bend and then cut it after.


Ask yourself why you don't believe in the other gods. Apply your answer to your current god. Boom! One step closer to world peace.

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#6 2016-01-16 11:18pm

its-all-good
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Re: The World is not round!! Homemade Square Cages

big_smile

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#7 2016-01-18 8:11am

buddhashenglong
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Re: The World is not round!! Homemade Square Cages

Very cool.


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#8 2016-01-18 8:36am

JonnyCruzR
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Re: The World is not round!! Homemade Square Cages

Great job.

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#9 2016-01-18 8:43am

kopwithit
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Re: The World is not round!! Homemade Square Cages

Great work Troy-Always Awesome pics and details with your Threads... Thanks for sharing your VooDoo secrets... wink Ride-On... Brother... Not cool to Be Square... lol lol XCs Forever... big_smile


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#10 2016-01-18 8:49am

holeshot
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Re: The World is not round!! Homemade Square Cages

This is why I am a member here, this rules!big_smile


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#11 2016-01-18 10:18am

G33K
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Re: The World is not round!! Homemade Square Cages

Where is your laser cutter??? lol


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#12 2016-01-18 3:00pm

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Re: The World is not round!! Homemade Square Cages

Very talented, great job      big_smile


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#13 2016-01-19 5:58am

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Re: The World is not round!! Homemade Square Cages

Very cool.

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#14 2016-01-19 8:39am

Coco
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Re: The World is not round!! Homemade Square Cages

Nice tech post. cool

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#15 2016-02-01 5:30pm

troynlori
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Re: The World is not round!! Homemade Square Cages

I need some input.  If I actually go into production on these, I need to decide a tooth pattern and a hole pattern for the middle of the cage.  Since these get cut on a CNC laser I can pretty much do as I please.  There are ramifications to the pattern I choose.  For example...put more holes, pay a higher price...  Just sketching around, I through some stuff on paper (see following).  #1 is like JP, and while I like this pattern, I see no need to replicate it here.  #2 is like Hutch.  I am not planning on making these so pointy.  5 is like Suntour XCII, 6 is like CRUPI, 7 is like original Revcore.  My favorite is along the lines of 4 & 9.

1) What's your idea for a pattern (either chosen below or suggest your own).

2) Is there a market.  This is not an FS thread and I'm not selling here...I don't even have nothing to sell.  I'm just interested to know either publicly or by PM if people see a real need because I have to make these things in bulk and it is a lot, a lot of work.  Just assume the price would be in the normal price range for cages.

https://s3.amazonaws.com/uploads.bmxmuseum.com/user-images/37108/teeth56b006bdcb.jpg


Hi.

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#16 2016-02-01 5:43pm

old bmx dad/Ted
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Re: The World is not round!! Homemade Square Cages

Good job.   You have some teal talent.


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#17 2016-02-11 6:23pm

troynlori
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Re: The World is not round!! Homemade Square Cages

Thanks Ted.


SO.................................................How bout those teethese?


Hi.

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#18 2016-02-11 6:37pm

83DB
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Re: The World is not round!! Homemade Square Cages

Shoot, make some diamond cutout ones to fit a mks bm-7 and I'll buy a pair. wink

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#19 2016-02-21 11:57am

Juzzy83
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Re: The World is not round!! Homemade Square Cages

Awesome mate, if you ever want to sell those JP bodies too, please knock on my inbox door

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#20 2016-10-05 4:09pm

BRICKOS2
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Re: The World is not round!! Homemade Square Cages

6

1

11

Teeth pattern options

smile

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#21 2016-10-05 5:44pm

BritUS
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Re: The World is not round!! Homemade Square Cages

4, 5 and 10

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#22 2016-10-05 5:52pm

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Re: The World is not round!! Homemade Square Cages

They look amazing! smile


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#23 2016-10-07 6:12am

jnkd427
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Re: The World is not round!! Homemade Square Cages

Now that's freakin Talent cool.....


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#24 2016-10-07 8:21am

CannoT
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Re: The World is not round!! Homemade Square Cages

***BOOM** and that's how business is done ! Well done ...love it ... Hell, make them all ...if I was smart I'd do it big_smile cool cool cool


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#25 2016-10-07 9:55am

skdevore
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Re: The World is not round!! Homemade Square Cages

Awesome work.

I'm leaning towards #5.


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