DIY: ZTL2 Front Brake Air Scoop

[TPEHAK]

Alright ladies and gentlemen, today is the day and the new hight performance mod has been finalized, installed, tested and works very well. I'm gonna show you how you can do your own front brake airscoop for your Buell XB ZTL 2 caliper so you can brake as hard and as long as you want and dominate on the streets and on the tracks and make people turn their heads wondering what is this thing on your brake.

First of all you will need the CAD model. Likely for you I already have this work done! You can download parts STL files here https://drive.google.com/file/d/1sP22VRTcTrUkUO7KOYGJ1X3s7FflAnoj/view?usp=sharing


Or if you want to use CAD model you can download Parasolid X_T file with all parts here https://drive.google.com/file/d/1MTjxLhZTPKDp6QnkbIlX_ke3uXl3E9Xg/view?usp=sharing

I designed the bracket of the airscoop to be attached to T-Rex Racing sliders https://www.buellxb.com/forum/showthread.php?46591-T-Rex-Racing-sliders

If you have another sliders or if you do now have sliders at all you have to think how you can attach the bracket to the front wheel hub. You can modify the Parasolid X_T file bracket CAD model and adjust bracket holes diameters specifically for your slider diameter, or you can can cut washers and spacers to attach the existing bracket to you slider.

Then you will need to find a FDM 3D printer. The parts I designed is optimized specifically for FDM 3D printers to get the best possible quality result. Sure you can print the parts using another 3D printing technologies, but this is the cheapest way to do these parts. I want to tnak www.pcs.design company for letting me to print my parts on their 3D printers.

Then you need to buy printing material. For the parts I currently have I used black color 1.75 mm PLA filament from eSUN https://www.amazon.com/gp/product/B01EKEMDA6/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1

But, PLA is not perfect for this application, it is biodegradable, not UV resistant, not the strongest and low glass transition temperature material. The only reason I used it is because it is easy and fast to print. Will see how it will perform in long run, but for the parts I would recommend to use PETG material, like this https://www.amazon.com/gp/product/B00ZAUQZTA/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1

PETG is tricky to print, takes long time, but once you have nailed the 3D printing settings you will have strong, heat resistant and UV resistant parts with good surface finish.

One roll of this material is enough to print a bunch of parts, so material expense is very cheap.

Now print the parts. Here is the picture how you have to orient the pars in the 3D printer bed.

No need to use support structure, no brim, no anything, parts are easy and reliable to print as is. For PLA material I used 0.4 mm nozzle diameter, 0.25 mm first layer thickness, 0.2 mm another layers thickness, 0.4 mm bead width, 215 C first layer temperature, 210 C another layers temperature, 3 layer wall thickness, 20% infill. Slow down a few first layers speed and then go default printing speed on the rest. I did not print from PETG filament so you are free for experiment with this material.

Then you need to buy fasteners

- 2 screws 316 Stainless Steel Button Head Hex Drive Screw Super-Corrosion-Resistant, 1/4"-20 Thread Size, 2-1/2" Long https://www.mcmaster.com/#98164a238/=1e0j1rb

- 2 nuts 18-8 Stainless Steel Narrow-Base Weld Nut 1/4"-20 Thread Size https://www.mcmaster.com/#90572A400

And low strength thread locker https://www.amazon.com/Loctite-5553...F8&qid=1533420265&sr=8-2&keywords=222+loctite

So now you have ready to install plug and play kit

 

[TPEHAK]

Now just attach the airscoop to your motorcycle. Do not forget to apply Loctite 222 on the fasteners. Do not overtighten the fasteners.

Enjoy next level braking performance with air cooled caliper!

 

[TPEHAK]

I'm sure somebody here who will print the parts for himself can print some extra parts for members. Let's make a user agreement, if somebody uses the files to print stuff for himself he has to print some extra parts for members for money or for free how he wish. This guy can 3D print https://www.buellxb.com/forum/showt...u-the-happiest&p=604263&viewfull=1#post604263

 

[Cooter]

I'm sure somebody here who will print the parts for himself can print some extra parts for members. Let's make a user agreement, if somebody uses the files to print stuff for himself he has to print some extra parts for members for money or for free how he wish.

OK, Cool! The guy you are describing as a screen name. It's TPEHAK. Should I PM him the user agreement?
:eagerness:

 

[user_deleted]

Alright ladies and gentlemen, today is the day and the new hight performance mod has been finalized, installed, tested and works very well. I'm gonna show you how you can do your own front brake airscoop for your Buell XB ZTL 2 caliper so you can brake as hard and as long as you want and dominate on the streets and on the tracks and make people turn their heads wondering what is this thing on your brake.

 

[badmotorscooter]

I think you can get those deer whistlers for around $7 at Walmart, no need to go through all that trouble.

 

[JeffY]

Even though I don't have any need for those scoops, you did a good job on them. Kudos to you!:up:

 

[njloco]

Teabag, Your chicken strips appear to be twice the size of mine, so I'm sure you really needed those to cool your brakes off !

P.S. we need more, even larger pictures please.

 

[TPEHAK]

This brake cooler allows you to keep higher speed for longer distance and start braking later and harder significantly reducing your traveling time. It is also very helpful and works effectively in mountain area like here in Seattle, where you can go downhill for extensive period of time and have to brake longer than you do it usually.

 

[user_deleted]

This brake cooler allows you to keep higher speed for longer distance and start braking later and harder significantly reducing your traveling time. It is also very helpful and works effectively in mountain area like here in Seattle, where you can go downhill for extensive period of time and have to brake longer than you do it usually.

 

[wickedchop]

If you would make a set of triples that will accept late model gsxr fork tubes LIKE I ASKED awhile ago, then you wouldn't need this contraption!!!!

 

[rchuff]

Once again it is a look at me thing. Don't even get why he posted the freaken pics!! Wait till the first bug hits it and it goes to pieces. Or the bug gets lodged in the opening. I hear they have big pests in Seattle.

 

[TPEHAK]

It is going to be fine. This thing already survived a few dozens miles on 50 mph highway and some bumpy roads. I will report you back how it performs when I will have more miles on it. If this thing can survive here in Seattle it can survive anywhere in the world. So stay tuned!

 

[SEXT9]

I think it's cool you're being innovative Tpehak. Thanks for sharing with us.

 

[njloco]

His lack of annunciation and ability to spell simple words amazes me, I don't think I've ever read one complete, coherent sentence from him, I doubt he's doing any of this work and this is why he's never made anything for anyone else, in other words, he's full of sh-t !

 

[RayAmsterdam]

Guys, what is the problem with some of you? The guy is taking time to engineer something for our beloved bikes. He even shares the blueprints for free so you can use them as you will. If you think the product is not for your need, no problem. But why react like this? What have you done yourself to keep Buell alive?
Tpehak: kudos for your time and effort!

 

[Outlaw]

He has a history of being a douche bag.

 

[user_deleted]

But why react like this?
historically he's the board troll...critic...braggard....and singular dick who busts on Buells at every opportunity. last month he advised some poor soul on here NEVER to buy a Buell because "they're junk and will leave you sit". but then you wouldn't be cognizant of any of his shenanigans because you're new.

What have you done yourself to keep Buell alive?
well let's see now: have helped hundreds if not thousands of board members diagnose problems....source parts....provided advice and counsel....provided impossible-to-find part numbers.....checked factory inventories for parts availabilities.
have shipped parts overseas on numerous occasions to board members who could not source them locally...all at dealer cost.
have given away free new and used parts....clothing....gear....tickets to motorcycle events.....endless goodies.
sell OEM and aftermarket parts at a few percentage points over dealer cost to help out board members on a tight budget. some of those sales even fell into the category of "pay me when you get the money".
have sold approx. 15 mint condition low mileage Buells to board members at extremely fair prices.
but that's just me.

 

[njloco]

Tickets, what tickets, I haven't seen any tickets ! I'm going to hang out with Teabag :sorrow:

 

[TPEHAK]

"they're junk and will leave you sit".

Sad, but true. But let's keep this discussion for another thread. Here we are talking about front brake air scoop and how drastically it can improve braking ability of your motorcycle.