Overview

To bore larger cylinder holes in preparation for sleeving the 2009 CBR600RR engine, the team needed a jig stiff enough to resist bending when subjected to the milling machine.

What I built

• I designed the jig on Solidworks, and selected a stock cast aluminum from a that matches the rigidity of the engine as closely as possible. The engine needs to go through similar torsion that it would feel on the jig as it would in action, and I designed with that constraint in mind.
• I roughly simulated the forces it may feel during the boring process, and the results are as shown above. These aren't the exact forces it would feel while being bored, but it gives a rough idea about how much deflection there is.

Result

This is still in progress!