Shifter brush seal test ride at Sabine ATV Park

[highpocket74]

Met some friends at Sabine ATV Park yesterday for some long overdue riding. Although this location is not idea for our style of trail riding, they do have some decent trails contradictory to the unlimited supply of mud and water holes. It’s was very hot and dusty yesterday.

However, those conditions made for an excellent day of testing something new we are working on. As I’ve said before, when inspiration hits, I must acknowledge it and entertain the idea.

My design partner and I spent most of last week during spare time for day jobs brainstorming ideas for sealing that shifter opening. I’d even talked with a manufacturer the week before about my idea, but after conversations and design sketch trading, they concluded they couldn’t make it how I wanted. So we came up with some ideas to try on our own using our 3d printers.

Friday I was installing the first rendition of our concept. It worked OK but I knew there was a better way. While studying the installation I had an idea but that required machining parts, which I don't have access to at this time. Then I went back to my original sketch idea that a manufacturer said they couldn't do. I had a new idea about that sketch so into the office I went to draw some cad models. It was freaking HOT outside anyway! The main design problem was how to hold the brushes in place? Within 2 hours I had a new prototype designed, 3d printed and installed for testing. And it worked! I had the design to test on Saturday's ride.

We've definitely got some refinement to do before releasing to the public but the concept worked during test riding. The brushes blocked nearly all of the air coming though the shifter plate openings even at highway speed. I'd like to test different brush materials also. Overall, I'm very pleased with the first day of testing. Installation was easy, even with this early prototype.

This design could be made to fit the OEM shifter plate also.

 

[Admin]

 

[Scrappapotamus]

Sweet. You thinking of making these for CATech plates as well?

 

[highpocket74]

I'm thinking this may work for those. I'd have to try it and see. The subframe opening is the same no mater what shifter plate covers it.

For the OEM plate, you'd have to remove the tab that hooks into the subframe.

 

[highpocket74]

Received samples of different brushes to try. The ones I'm currently testing with have larger bristles and they seam to bend more than I'd like. The new sames have thinner bristles that are more flexible. I've got the brush holder redesigned to 3d print and test these new brushes soon. If they work as well as the first test set, then these will be a popular product to block incoming air.

I have a CA Tech plate that I can check these with, Scrap. I think it will work fine though. Will also test with the OEM plate for those who may not want to change the plate at all.

 

[SLOWPOKE693]

Trying to turn a SxS into a Jeep or Bronco is never going to work..... 😆

 

[Hello_Darkness]

Trying to turn a SxS into a Jeep or Bronco is never going to work..... 😆

I'm waiting for a bubble for my dirtbike.

 

[highpocket74]

Sweet. You thinking of making these for CATech plates as well?

I've got a viable solution for my shifter plate design. Installed 3 kits on talons this weekend to run for a little while. New brushes are softer and return to position better. I've designed a thin, 2 piece plastic piece that I 3d printed which sandwiches the brushes and that assembly gets bolted down under the shifter plate.

Yesterday evening the wife and I rode a few miles to catch a nice sunset along the river. The brushes do a FANTASTIC job of blocking the air through the shifter openings at 40 mph.

I started looking at adapting the brush setup for the OEM shifter plate. This will require larger brushes. This may also work for CA Tech plates.

I'm expecting some sheet metal pieces from the shop this week so that will be priority.

 

[highpocket74]

The plan at the moment is to get these ready for sale soon. Getting an order in for some brush material soon and will begin 3d printing the brush holders soon. These brushes will only work with my narrow shifter plate design at this time. I'll have to work on something else for the factory shifter plate and possibly the CA Tech plate also.

My first concern was if the brushes would get frayed and stay like that but they are returning to position very well after a couple weeks of being on 3 machines. They may be messed up for a short period of time but so far have been closing the gap and I'm happy with them. I'm very impressed with how they block air coming through.

 

[Remington]

These brushes will only work with my narrow shifter plate design at this time.

How about with the AJK offroad shift gate? Its very similar to yours. Im asking cuz thats what i have. Bought it before your came out with yours.

 

[highpocket74]

Once I figure out the ca tech then this should be very similar

 

[highpocket74]

The 3D printer is running this weekend making shifter brush seal parts in anticipation of receiving the brushes soon.

This first design out the gate will work for my shifter plates.

Next up will be for an OEM shifter plate, which requires different size brushes. Samples for that size are coming with my brush order.

So far these have been working great on our 3 test talons.

 

[SLOWPOKE693]

Very cool! 😎

 

[highpocket74]

Cad model exploded view.

 

[highpocket74]

This is the current OEM shifter brushes being tested on mine. They work well at highway speeds. Because the bristles are long and soft (to return to original position) they also get a little wild and jump outside the shifter slots. So far that's the only downside. Also, after sitting for a week, and the bristles being pushed around the shift lever I was surprised at how quickly they return to position and continue to seal the area.

The Park position kinda screws up the way it would work the best, with less width to cover and shorter bristles. I am happy with the R, N,D, and L positions. The split in the brush halves works perfectly at those positions.

 

[SLOWPOKE693]

Very cool.

 

[highpocket74]

Here's my plan for the release of this product which will fit my DT-S1 shifter plate:

1. For new DT-S1 purchases, I'll turn on an automatic discount so that when someone adds a DT-S1 Talon shifter plate to their cart, they will see a discount offer to add the brush seal kit to the order. I will also phase out remaining stock of colored shifter plates. The textured black (a very nice finish) sells the best so I'll focus on that product. I will keep some unpainted blanks available for anyone that wants to have custom painted themselves.

2. For customers who have already purchased a DT-S1 shifter plate, I will send an email to all registered customers notifying of the product availability and include a coupon code to purchase.

3. The brush seal kit will be listed as a stand alone product at full price.

I have 10 frames 3d printed and ready to ship with brushes. Printing continues. Waiting on the new longer bolts to arrive later this week or early next week. The OEM bolts are barely not long enough. The brush seal is 4mm thick.