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DKW 300 Luxus Blutbase

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New building kit for big boys (and girls too, of course) :)
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updated December 8, 2025

Description

This time I have prepared for you a model of the DKW 300 Luxus motorcycle, nicknamed Blutbase (blister) for its bright red tank.
The motorcycle was produced between 1929 and 1933 and about 6000 units were produced.
The model itself is drawn in a scale of 1:3, the same as my previous model of the motorcycle Jawa-ČZ 250/353.02. So they can complement each other on the shelf.

When building the model, the same applies as for the Jawa. That is - the model consists of many very small parts, so assemble carefully and cautiously. It is often worth “welding” the parts with a soldering gun instead of gluing them with superglue.

As for the necessary tools, you cannot do without micro screwdrivers, tweezers, pliers, soldering gun and clamps. Use good quality PLA or TPU. You will need about 1KG of black glossy PLA, 0.5kg of silver (chrome) and gray PLA. Also about 300g of black matte PLA or TPU (tires) and the same amount of red and yellow PLA. About 100g of blue and brown PLA.

For the best resalts I recommend all parts print with 0.2-0.25mm nozzle and 0.15-0,08 layer. All parts is possible to print on plate for Prusa Mk3 and Mk4.

If something in the instructions and attached pictures is not clear to you, you can try looking at the gallery of my model construction: 3D tisk DKW 300 Luxus Blutbase – jawarmaniak – album on Rajče

But enough about the introduction, now on to the construction itself:

1.THE FRAME

Printing instructions:

  • Bearing_cup - 2 pcs, silver/chrome PLA, 100% infill, 0,15 layer

  • R_front_frame - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • L_front_frame - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • R_underseat_frame - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • L_underseat_frame - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • R_top_frame - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • L_top_frame - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • head_frame - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • gearbox_holder - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • R_engine_plate - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • L_engine_plate - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • Frame_spacer_1 - 7 pcs, black silk PLA, 100% infill, 0,15 layer

  • Frame_spacer_2 - 3 pcs, black silk PLA, 100% infill, 0,15 layer

  • Frame_spacer_3 - 3 pcs, black silk PLA, 100% infill, 0,15 layer

  • Frame_spacer_4 - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • Stearing_stopper - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • Engine_holder - 1 piece, black silk PLA, 100% infill, 0,15 layer

Assembly instruction:

  1. Glue both Bearing_cups into head_frame.

  2. Screw the entire frame together gradually according to the attached picture.

 

2.THE FRAME NECK

Printing instructions:

  • Grease_nipple -  4 pcs, silver/chrome PLA, 100% infill, 0,15 layer

  • Steering_damper_spring -  1 piece, silver/chrome PLA, 100% infill, 0,15 layer

  • Steering_damper_catch -  1 piece, silver/chrome PLA, 100% infill, 0,15 layer

  • Frame_neck - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • Top_bearing_cup - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • Upper_steering_clamp - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • Stearing_damper_carrier - 1 piece, black silk PLA, 50% infill, 0,15 layer

  • Steering_damper_cup - 2 pcs, black silk PLA, 100% infill, 0,15 layer

  • Steering_damper_nut - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • Steering_damper_plate - 2 pcs, brown PLA, 100% infill, 0,15 layer

 

Assembly instruction:

  1. Glue the threaded rod M3-72 into the Frame_neck.

      2. Glue 2 pieces of Grease nipple into Frame_neck and 2 pieces into Upper_steering_clamp.

     3. Put some Vaseline in the frame bearing cups and put 16 pieces of 2mm diameter bearing balls in each of the cup.

    4. From bottom side slide Frame_neck into the frame head assembly. From the top side on the Frame_neck slide in gradually Top_bearing_cup and the Upper_stearing_clamp.

    5. Insert M3 nut into the Stearing_damper_carrier and screw this subassembly on the threaded rod M3 (glued into the Frame_neck). Tighten lightly by hand and try turning the steering neck in the frame. If it is stiff, loosen slightly. If it has play, tighten slightly.

   6. Once you are satisfied with the freedom of rotation of the neck, insert an M3-16 bolt with a washer under the head into the Upper_steering_clamp and tighten it with a nut over the second washer. This will fix the steering neck and hold it in place. After that you can unscrew the Stearing_damper_carrier from the threaded rod.

   7.  Slide the Steering_damper_cup, Steering_damper_plate, Steering_damper_catch, Steering_damper_plate and Steering_damper_cup onto the threaded rod in sequence. Screw in the Steering_damper_carrier and tighten.

   8. Slide the Steering_damper_spring and screw the Steering_damper_nut onto the end of the threaded rod.

 

3.THE FRONT FORK ROCKER ARMS

Printing instructions:

  • Upper_rocker_arm -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Lower_rocker_arm -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Spacer_1 -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Spacer_2 - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • Spacer_3 - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • Spacer_4 - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • Upper_spring_screw - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • Lower_spring_screw - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • Lower_spring_holder - 1 piece, black silk PLA, 100% infill, 0,15 layer

  • Handlebars_holder - 2 pcs, black silk PLA, 50% infill, 0,15 layer

  • Grease_nipple - 2 pcs, black silk PLA, 100% infill, 0,15 layer

  • Front_fork_spring - 1 piece, silver/chrome PLA, 100% infill, 0,15 layer

 

Assembly instruction:

  1. Glue 2 pieces of Grease nipple into Lower_rocker_arm and into Upper_rocker_arm.

  2. Connect the Lower_spring_screw and Lower_spring_holder together with an M3-10 screw, which you screw in from the bottom side.

  3. Slide Handlebar_holders onto the Upper_steering_clamp from both sides and tighten each of them with 2 pcs of M2.5-10 screws with a nut from the bottom side. You don't need to tighten them, you will need to loosen them when installing the handlebars.

  4. Install Upper_rocker_arm on its place and insert the Spacer_4 into it from right side. Insert into Spacer_4 threaded rod M3-52.

  5. Insert Spacer_1 on its place

  6. Screw the Upper_spring_screw onto the Front_fork_spring.

  7. Screw the Front_fork_spring onto the Lower_spring_screw.

  8. Insert Spacer_3 into frame neck. Connect the Upper_spring_screw and Upper_steering_clamp together with an M2.5-14 screw, which you screw in from the top side. Insert threaded rod M3-50 throught Lower_rocker_arm and the Spacer_3. Insert from both side washer and screw nuts. Tighten the nuts and make sure that the Lower_rocker_arm can rotate freely.

  9. Thread Spacer_2 through Lower_spring_holder and Lower_rocker_arm. Insert M3-60 threaded rod.

  10. Insert Spacer_1 and M3-60 threaded rod into Upper_rocker_arm.

 

4.THE FRONT FORK

Printing instructions:

  • R_front_fork -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • L_front_fork -  1 piece, black silk PLA, 100% infill, 0,15 layer

 
Assembly instruction:

  1. Screw both sides of the front fork on their place by 4xM3 nuts with washers and with 2 pieces of the M1.6-4 screws with nuts.

  2. After tightening the M3 nuts, check that the front fork can move freely.

 

4.THE SUSPENSION DAMPER

Printing instructions:

  • Suspension_damper_end_cap -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Suspension_damper_nut -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Suspension_damper_catch -  2 pcs, black silk PLA, 100% infill, 0,15 layer

  • Friction_plate_1 -  1 piece, brown PLA, 100% infill, 0,15 layer

  • Friction_plate_2 -  1 piece, brown PLA, 100% infill, 0,15 layer

  • Suspension_damper_spring -  1 piece, silver/chrome PLA, 100% infill, 0,15 layer

 
Assembly instruction:

  1. Pull out the M3-52 threaded rod from the Spacer_4.

  2. Glue the threaded rod into the Suspension_damper_end cup.

  3. Slide the Suspension_damper_catch and Friction plate_1 onto the threaded rod.

  4. Insert this assembly into the Spacer_4 from the leftside.

  5. Insert the Friction_plate_2, Suspension_damper_catch and Suspension_damper_spring from the right.

  6. Screw the Suspension_damper_nut onto the end of the threaded rod.

 

5.THE FRONT MUDGUARD

Printing instructions:

  • Front_mudguard -  1 piece, black silk PLA, 100% infill, 0,15 layer

 

Assembly instruction:

  1. Install the front mudguard into the front fork. Screw 2x M1.6-5 + nuts and 2x M2-5

 

6.THE REAR MUDGUARD

Printing instructions:

  • Rear_mudguard -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Luggage_carrier -  1 piece, black silk PLA, 100% infill, 0,15 layer

 

Assembly instruction:

  1. Screw together Rear_mudguard and Luggage_carrier by 2 pieces of M2-5 screws with nuts.

  2. Insert the rear fender into the frame and screw it into place at the rear wheel axle with two pieces of M2-5 bolt and nut. Insert a piece of M3 threaded rod through the hole under the seat or insert an M3 bolt to temporarily fix it in place.

 

7.THE SECONDARY CHAIN COVER

Printing instructions:

  • Secondary_chain_cover -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Holder  -  1 piece, black silk PLA, 100% infill, 0,15 layer

 

Assembly instruction:

  1. Remove the M3-40 screw from the frame. Insert the Holder and put the screw back in its place.

  2. Slide the Secondary_chain_cover into the frame and secure it with the M2-4 screw with nut and the M2-5 screw with nut.

 

8.THE MAIN STAND

Printing instructions:

  • R_stand -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • L_stand  -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Stand_spacer -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Stand_pedal  -  1 piece, black silk PLA, 100% infill, 0,15 layer

 

Assembly instruction:

  1. Glue the M3-60 threaded rod into the Stand_pedal.

  2. Screw the L_stand, Stand_spacer and R_stand onto the threaded rod in turn. If necessary, fix the entire stand assembly with glue.

  3. Remove the M3-15 screw from the frame and insert the stand in its place. Thread the M3-32 threaded rod through the hole and insert the M3 nuts on both sides.

  4. Thread the return springs.

 

9.THE TOOL BOXES

Printing instructions:

  • Lock_cap -  2 pcs, black silk PLA, 100% infill, 0,15 layer

  • Lock -  2 pcs, black silk PLA, 100% infill, 0,15 layer

  • Box -  2 pcs, black silk PLA, 100% infill, 0,15 layer

  • Lid_black  -  2 pcs, black silk PLA, 100% infill, 0,08 layer (0.25 nozzle is necessary)

  • Lid_yellow  -  2 pcs, black silk PLA, 100% infill, 0,08 layer (0.25 nozzle is necessary)

  • Lid_blue  -  2 pcs, black silk PLA, 100% infill, 0,08 layer (0.25 nozzle is necessary)

Lid_black/yellow/blue is necessary import into slicer together = multicolor print = MMU unit or AMS is required.

The following settings worked well for me when printing the cap:

  • 1st layer 0.12

  • layers 0.08

  • infill 100%

  • gap above supports in Z axis 0.12

Assembly instruction:

  1. Thread the Lock through the hole in the Lock_cap and glue the assembly to the marked location in the Box. Make sure that the Lock can move and tilt freely. 

  2. Slide the Lid onto the Box and thread a 38mm long piece of wire through the hole in the hinges. If necessary, grind the hinges so that they fit snugly. Make sure that the Lid can rotate freely throughout its entire range.

  3. Mount the Box to the Luggage_carrier using 4 pieces of the M1.6-4 screws.

  4. Assemble the box on the other side of the motorcycle in the same way.

 

10.THE FRONT WHEEL

For assembly of the complete front wheel you have to combine model from the folders “WHEELS”, “FRONT WHEEL HUB” and “Brake LEVERS”. The wheels are the most complex part of the entire construction, so be especially careful when building and follow the instructions carefully. Also see the photos in the photo gallery. 3D tisk DKW 300 Luxus Blutbase – jawarmaniak – album on Rajče

Printing instructions:

  1.  Folder “WHEELS”

  • Rim -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Wheel_nipple -  36 pcs, chrome/silver PLA, 100% infill, 0,15 layer

  • Wheel_hub_cap -  2 pcs, black silk PLA, 100% infill, 0,15 layer

  • Bearing_cap  -  2 pcs, black silk/grey PLA, 100% infill, 0,15 layer

  • Tire_1  -  1 piece, black matte PLA/TPU, 100%/75% infill, 0,15 layer

  • Tire_2  -  1 piece, black matte PLA/TPU, 100%/75% infill, 0,15 layer

  • or Tire_complete  -  1 piece, black matte PLA/TPU, 100%/75% infill, 0,15 layer

  • Wheel_valve_body  -  1 piece, black matte PLA/TPU, 100%/75% infill, 0,15 layer

  • Wheel_valve_cap -  1 piece, chrome/silver PLA, 100% infill, 0,15 layer

  • Wheel_valve_nut -  1 piece, chrome/silver PLA, 100% infill, 0,15 layer

      2. Folder “FRONT WHEEL HUB”

  • Front_wheel_brake_shield -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Front_wheel_hub_1 -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Front_wheel_hub_2 -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Front_wheel_spacer  -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Front_wheel_assembly_tool  -  1 piece, PLA, 8% infill, 0,2-0,15 layer

      3. Folder “BRAKE LEVERS”

  • Shim -  1 piece, chrome/silver PLA, 100% infill, 0,15 layer

  • Brake_lever -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Front_wheel_brake_key -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Cable_hanger  -  2 pcs, black silk PLA, 100% infill, 0,15 layer

 

Assembly instruction:

  1. Glue together Rim, Wheel_valve_nut, Wheel_valve_body, Wheel_valve_cap. 

     2. Glue together Front_wheel_hub_1 and Front_wheel_hub_2. Make sure that the spoke holes in both parts          are aligned.

     3. Prepare wires with a diameter of 1mm and a length of approximately 75mm. Bend the ends using pliers          as shown in the picture.

     4. Insert the wheel hub into the Assembly_tool with the brake drum facing down. Then insert the rim and            rotate it so that the valve is aligned with the hub as shown in the picture.

     5. Thread the spokes of the wheel so that each subsequent spoke, located at the same distance on one              side of the hub, alternates three holes in the rim.

      6. Fix the ends of the wires in the hub with glue.

      7. After the glue dries, insert the Wheel_nipples from the inside of the rim and fix everything with glue.

      8. Remove any excess wire ends.

         9. Fix the Cable_hanger to the Brake_lever using the M2-5 screw.
         10. From the inside, slide the Front_wheel_brake_shield into the Front_wheel_brake_key. From above,                      slide the spring made of ø1 wire, Brake_lever, Shim and fix everything with the M1.6-4 screw

       11. Glue the Tire_complete or Tire_1 + Tire_2 into the rim.

       12. Insert 12 pcs of ø2 bearing balls into the wheel hub from both sides and fix them with petroleum jelly.

       13.  Place the Bearing_cap and Wheel_hub_cap on the balls.

       14. Insert the M3-60 threaded rod.
       15. slide on the brake shield assembly and Front_wheel_spacer onto the threaded rod.


       16. Screw the Cable_hanger to the right side of the front fork (above the fender mount) of the motorcycle              using an M2-5 screw.

       17. Insert the assembled wheel into the front fork of the motorcycle. Slide the washers on the outside                    and secure everything with M3 nuts. After tightening, make sure that the front wheel can rotate                      freely.

 

11.THE REAR WHEEL

For assembly of the complete front wheel you have to combine model from the folders “WHEELS”, “FRONT WHEEL HUB” and “Brake LEVERS”. The wheels are the most complex part of the entire construction, so be especially careful when building and follow the instructions carefully. Also see the photos in the photo gallery. 3D tisk DKW 300 Luxus Blutbase – jawarmaniak – album on Rajče

Printing instructions:

  1.  Folder “WHEELS”

  • Rim -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Wheel_nipple -  36 pcs, chrome/silver PLA, 100% infill, 0,15 layer

  • Wheel_hub_cap -  2 pcs, black silk PLA, 100% infill, 0,15 layer

  • Bearing_cap  -  2 pcs, black silk/grey PLA, 100% infill, 0,15 layer

  • Tire_1  -  1 piece, black matte PLA/TPU, 100%/75% infill, 0,15 layer

  • Tire_2  -  1 piece, black matte PLA/TPU, 100%/75% infill, 0,15 layer

  • or Tire_complete  -  1 piece, black matte PLA/TPU, 100%/75% infill, 0,15 layer

  • Wheel_valve_body  -  1 piece, black matte PLA/TPU, 100%/75% infill, 0,15 layer

  • Wheel_valve_cap -  1 piece, chrome/silver PLA, 100% infill, 0,15 layer

  • Wheel_valve_nut -  1 piece, chrome/silver PLA, 100% infill, 0,15 layer

      2. Folder “REAR WHEEL HUB”

  • Rear_wheel_brake_shield -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Rear_wheel_hub_1 -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Rear_wheel_hub_2 -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Rear_wheel_spocket  -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Rear_wheel_assembly_tool  -  1 piece, PLA, 8% infill, 0,2-0,15 layer

      3. Folder “BRAKE LEVERS”

  • Shim -  1 piece, chrome/silver PLA, 100% infill, 0,15 layer

  • Brake_lever -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Front_wheel_brake_key -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Cable_hanger  -  1 pcs, black silk PLA, 100% infill, 0,15 layer

 

Assembly instruction:

  1. The rear wheel is constructed in a similar way to the front wheel. Assemble the wheel valve, wheel hub and brake shield in the same way and make the spokes. 

  2. Screw the Rear_wheel_spocket to the wheel hub using 6 pieces of M2-4 screw.

  3. Thread the M3-62 threaded rod through the wheel hub and place the wheel in the motorcycle frame.

  4. Slide the washers on both sides and secure with M3 nuts.

  5. Make sure the rear wheel can rotate freely and does not catch on the fender or chain guard.

        6. Screw 2 pieces of M2.5-22 screw into the frame as a “chain tensoniers”.

 

12.THE ENGINE

12a. Crankcase

Printing instructions:

  • L_Crankcase-  1 piece, grey PLA, 50% infill, 0,15 layer

  • R_Crankcase  -  1 piece, grey PLA, 50% infill, 0,15 layer

  • Crankcase_cap -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Intake_duct  -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Cylinder  -  1 piece, black matte PLA, 50% infill, 0,15 layer

  • Head -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Head_holder -  2 pcs, black silk PLA, 100% infill, 0,15 layer

 

Assembly instruction:

  1. Insert 3 pieces of the ball bearing 686ZZ into crankcase.

  2. Screw Intake_duct and the Cylinder together by M2.5-8 and M2.5-20 threaded rod with nut (threaded rods glue into the Cylinder).

  3. Glue 4 pieces of threaded rod M3-26 into the holes in the cylinder (for screw a head).

  4. Glue 2 pieces of threaded rod M3-32 into the holes in the cylinder (for screw a exhaust chamber).

  5. Glue 2 pieces of threaded rod M2-8 into the holes in the L_crancase and the R_crankcase for screwing the cylinder. You can screw 4 pcs of screw M2-10 and cut the heads.

  6. Do not screw the individual parts together yet.

 

12b. Crankshat

Now you need to decide if you want to print the complete crankshaft, which is not visible and therefore not completely needed for the motorcycle assembly. You can print just the pins with the flywheel. Otherwise, you will also be making a piston with a working connecting rod.

Printing instructions:

  • Sprocket -  1 piece, grey PLA, 100% infill, 0,15 layer

  • L_flywheel -  1 piece, grey PLA, 50% infill, 0,15 layer

  • R_flywheel -  1 piece, grey PLA, 50% infill, 0,15 layer

  • L_pin -  1 piece, silver/chrome PLA, 100% infill, 0,15 layer

  • R_pin -  1 piece, silver/chrome PLA, 100% infill, 0,15 layer

  • Connecting_rod_pin -  1 piece, silver/chrome PLA, 100% infill, 0,15 layer

In case you are building a complete crankshaft:

  • Piston_pin -  1 piece, silver/chrome PLA, 100% infill, 0,15 layer

  • Connecting_rod -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Piston -  1 piece, white PLA, 50% infill, 0,15 layer

  • Piston_ring -  4 pcs, black PLA, 100% infill, 0,15 layer

Assembly instruction:

  1. Cut the M4 thread in the L_pin and R_pin.

  2. Glue together L_pin + L_flywheel and R_pin + R_flywheel

  3. Glue together L flywheel assembly, R flywheel assembly and Connecting_rod_pin.

In case you are building a complete crankshaft:

       3a. Skip point 3.
       3b. Glue the Connecting_rod_pin into the left flywheel assembly.
       3.c Slide the Connecting_rod and bearing rollers onto the Connecting_rod_pin. Lubricate them with                      Vaseline.
       3d. Glue the right flywheel assembly.
       3e. Slide 4x Piston_ring onto the Piston.
       3f.  Connect the piston to the connecting rod using the Piston_pin.

       4. Slide the crankshaft into the bearings in the crankcase.
       5. Screw together both pieces of the crankcase.
       6. Screw the Crankcase_cap.
       7. Slide the Cylinder and secure it with nuts.
       8. Install the Cylinder head and secure it with nuts and washers.
       9. Slide the Sprocket and M4 washer onto the L_pin. Tighten the M4 nut

 

12c. IGNITION

Printing instructions:

  • Rotor -  1 piece, grey PLA, 30% infill, 0,15 layer

  • Rotor_2 -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Rotor_cap -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

Assembly instruction:

  1. Slide Rotor and M4 shim onto the R_pin and screw M4 nut.

  2. Insert Rotor_2 into Rotor.

  3. Insert Rotor_cap and screw it by 2 pieces of M1.4-10 screw.

  4. Screw 4pcs of M1.4-2 into holes in Rotor from outside.

 

13.THE GEARBOX

Now you need to decide if you want to print the complete gearbox with gears, which are not visible and therefore not completely needed for the motorcycle assembly. You can print just the empty gearbox. Otherwise, you will also be making a functional gearing mechanism.

Printing instructions:

  • Gearbox_case -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Gearbox_cap -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Gear_shaft -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer (I recommend 0.25 nozzle)

  • Main_shaft  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer (I recommend 0.25 nozzle)

  • Output_gear -  1 piece, grey PLA, 100% infill, 0,15 layer (I recommend 0.25 nozzle)

  • Sprocket -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

In case you are building a complete gearbox:

  • Gear_1  -  1 piece, grey PLA, 100% infill, 0,15 layer (0.25 nozzle is necessary)

  • Gear_2  -  1 piece, grey PLA, 100% infill, 0,15 layer (0.25 nozzle is necessary)

  • Gear_3  -  1 piece, grey PLA, 100% infill, 0,15 layer (0.25 nozzle is necessary)

  • Gear_4  -  1 piece, grey PLA, 100% infill, 0,15 layer (0.25 nozzle is necessary)

  • Gearshift_fork  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer (I recommend 0.25 nozzle)

  • Countershaft  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer (I recommend 0.25 nozzle)

Assembly instruction:

  1. Cut an M5 thread in the bottom hole of the Gearbox_case and screw in an M5-5 screw.

  2. Glue an M3-20 threaded rod into the two top holes.

  3. Cut an M8 thread in the Output_gear and in the Sprocket.

In case you are building an uncomplete gearbox:

       4. Insert the 688ZZ ball bearing into the Gearbox_case.
       5. Insert the Output_gear into the bearing and screw the Sprocket from the outside.
       6. Insert the 683ZZ bearing into the Gearbox_cap.
       7. Insert the Main_shaft and Gear_shaft and close the Gearbox_Cap.
       8. Fasten the Gearbox_cap with 3 M1.6-6 screws.

In case you are building an uncomplete gearbox:

       4. Insert the 688ZZ and 683ZZ ball bearings into the Gearbox_case.
       5. Insert the Output_gear into the bearing and screw the Sprocket from the outside.
       6. Insert the 683ZZ bearing and K7x10x10 ceedle cage into the Gearbox_cap.
       7. Insert the Main_shaft and Countershaft with all gears into gearbox. 
       8. Insert the Gear_shaft with Gearshift_fork and close the Gearbox_Cap.
       9. Fasten the Gearbox_cap with 3 M1.6-6 screws.

 

  1. Insert the engine into the frame and secure it with 3 pcs of M3-16 screws and nuts.

  2. Insert the gearbox into the frame and secure it with 2 M3 nuts and washers

  3. Insert the Head_holder on both sides of the cylinder head and secure them with M2-5 screws on one side and M2.5-20 with nuts on the other side

  4. Adjust the steering stop and tighten it to the frame.

 

14.CLUTCH

Printing instructions:

  • Clutch_sprocket -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer (I recommend 0.25 nozzle)

  • Attachment_pad -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Clutch_nut -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Buttress_cap  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Ending_nut -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Clutch_carrier -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Spring_sleeve  -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Clutch_basket  -  1 piece,  silver / chrome PLA, 60% infill, 0,15 layer

  • Pressure_cup  -  1 piece, silver / chrome PLA PLA, 100% infill, 0,15 layer

  • Cover_plate  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Friction_plate  -  2 pcs, brown PLA, 100% infill, 0,15 layer (I recommend 0.25 nozzle)

  • Steel_plate  -  3 pcs, silver / chrome PLA, 100% infill, 0,15 layer

  • Insert  -  3 pcs, gold / bronze PLA, 100% infill, 0,15 layer

  • Flexible_element  -  3 pcs, black matte PLA or TPU, 100% / 40% infill, 0,15 layer

Assembly instruction:

  1. Insert the Clutch_carrier into the Clutch_spocket and secure it from the back with the Attachment_pad.

  2. Insert the Insert into the Flexible_element and then this assembly insert 4x into the Clutch_procket. Place the Clutch_basket from above and the Cover_plate from below. Screw everything together using 4 M1.6-5 screws with a nut.

  3. Slide this assembly onto the gearbox shaft and secure it by gluing the Clutch_nut. You can glue the Clutch_carrier also.

  4. Slide the Spring_sleeve and insert the spring into it. Secure it by gluing the Ending_cup to the end of the gearbox shaft.

  5. Prepare a wire with a diameter of 1mm and a length of 63 mm. Melt a ball of filament at the end and insert this wire into the inner cavity of the shaft.

  6. Insert the Steel_plate, Friction_plate, Steel_plate, Friction plate and Steel_plate into the Clutch_basket one by one.

  7. Install the Pressure_cap and Buttress_cap. Secure it with a drop of glue.
    The clutch should be functional, i.e. when you push on the wire in the transmission shaft, the central spring should be compressed and the clutch should "open".

 

15.PRIMARY TRANSMISSION COVER

Printing instructions:

  • Primary_transmision_cover -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Grease_nipple -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

Assembly instruction:

  1. Glue Grease_nipple into hole in the Primary_transmission_cover.

  2. Screw the cover on correct place by 2 M2.5-6 screws and one nut.

 

16.FOOTRESTS

Printing instructions:

  • L_footrest -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • R_footrest -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Insert_frame -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Footrest_rubber  -  2 pcs, black matte PLA or TPU, 100% / 40% infill, 0,15 layer

  • Brake_pedal -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Brake_rod_nut -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

Assembly instruction:

  1. Glue the threaded rod M3-73 into the L_footrest.

  2. Glue the threaded rod M3-70 into the R_footrest.

  3. Insert the Insert_frame into the frame, push the threaded rod M3-24 through the hole and slide the L_footrest and R_footrest. Tighten the M3 nuts on both sides.

  4. Slide the Footrest_rubber onto the threaded rod in the L_footrest and tighten with the M3 nut.

  5. Slide the Brake_pedal and Footrest_rubber onto the P_footrest and tighten with the M3 nut. Make sure that the pedal can rotate.

  6. Shape the wire into a brake rod and attach it to the pedal and the brake lever on the rear wheel. Slide the Brake_rod_nut onto the end.

 

17.EXHAUST

Printing instructions:

  • Exhaust_chamber -  1 piece, black matte PLA, 60% infill, 0,15 layer

  • Fishtail -  1 piece, black matte PLA, 100% infill, 0,15 layer

  • Exhaust_silencer -  1 piece, black matte PLA, 100% infill, 0,15 layer

  • Pipe_clamp  -  1 piece, black matte PLA, 100% infill, 0,15 layer

  • Exhaust_pipe_nut -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Exhaust_pipe -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

Assembly instruction:

  1. Use two M3 nuts and washers to attach the Exhaust_chamber to the cylinder.

  2. Insert the Fishtail into the Exhaust_silencer and secure it with a Pipe clamp and an M2-4 screw and nut. You can also use a little glue if necessary.

  3. Put the Exhaust_pipe_nut on the Exhaust_pipe and insert the whole thing into the Exhaust_silencer from the front side.

  4. Slide the exhaust pipe onto the Exhaust_chamber, press the Exhaust_pipe_nut and secure the Exhaust_silencer to the frame with an M2.5-4 screw.

 

18.CARBURETOR

Printing instructions:

  • Carburetor_body -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Intake_clamp -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Carburetor_cap_nut -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Carburetor_cap -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Floating_chamber -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Bottom_nut -  1 piece, gold / brass PLA, 100% infill, 0,15 layer

  • Floating_pin  -  1 piece, black PLA, 100% infill, 0,15 layer

  • Air_filter_body  -  1 piece, black PLA, 100% infill, 0,15 layer

  • Filter_clamp  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Air_filter_grid  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

Assembly instruction:

  1. Screw the M3-20 threaded rod into the Bottom_nut.

  2. Slide the Floating_chamber onto the threaded rod and screw the whole into the Carburetor_body from below.

  3. Glue the Floating_pin into the Carburetor body.

  4. Slide the Carburetor_cap into the Carburetor_cap_nut and press the whole into the Carburetor_body from above.

  5. Place the Intake_clamp on the front of Carburetor_body.

  6. Glue the Air_filter_grid into the Air_filter_body.

  7. Install the Filter_clamp. Install the Air filter onto the carburetor and tighten the Filter_clamp using the M1.4 screw and nut.

  8. Install the carburetor onto the intake neck and tighten the Intake_clamp using the M1.4-5 screw and nut.

 

18.TRANSMISSION CONTROL LEVERS

Printing instructions:

  • Gear_lever_puley_cap -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Gearing_insert -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Gear_lever_puley_holder -  1 piece, grey  PLA, 100% infill, 0,15 layer

  • Gear_lever_puley -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Gear_lever -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Gear_lever_ball -  1 piece, brown PLA, 100% infill, 0,15 layer

  • Gear_lever_rod  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Small_gear_lever_puley  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  •  

  • Starter_lever  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Top_starter_lever_pin  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Starter_rubber  -  1 piece, black matte PLA / TPU, 100% infill, 0,15 layer

  • Starter_rubber_stopper  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Starter_shim  -  1 piece, grey PLA, 100% infill, 0,15 layer

  • Spring_cover  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Starter_lever_pin  -  1 piece, grey PLA, 100% infill, 0,15 layer

  •  

  • Clutch_lever  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Clutch_screw  -  1 piece, grey PLA, 100% infill, 0,15 layer

Assembly instruction:

  1. Place the Small_gear_lever_pulley on the gearbox shaft and tighten it in place with the M1.6-5 screw.

  2. Insert the Clutch_screw into the gearbox hole and mount the Clutch lever. Tighten it with the M1.6-5 screw.

  3. Insert the Starter_lever_pin into the gearbox hole and fix it in place by gluing the Starter_shim.

       4. Install the Spring_cover.
       5. Glue the Top_starter_lever_pin into the Starter_lever.
       6. Install the Starter_rubber and secure it in place by gluing the Starter_rubber_stopper.
       7. Slide the lever onto the shaft and secure it with the M2-10 screw and nut.

       8. Glue the Gearing_insert into the Gear_lever_puley_holder.
       9. Screw this assembly to the gearbox with two M1.6-5 screws
       10. Insert the Gear_lever_puley_cap from the back.

       12. Place the Gear_lever_pulley and screw the M3-15 screw in the center.
       13. Screw the Gear_lever onto the Gear_lever_pulley using 4 M1.4-3 screws.
       14. Glue the Gear_lever_ball onto the end of the Gear_lever.
       15. Mount the Gear_lever_rod using two M1.6-5 screws.

 

20.FUEL TANK

Printing instructions:

  • Fuel_tank_red -  1 piece, red silk PLA, 100% infill, 0,08 layer (0.25 nozzle is necessary)

  • Fuel_tank_yellow -  1 piece, yellow silk PLA, 100% infill, 0,08 layer (0.25 nozzle is necessary)

  • Fuel_tank_black -  1 piece, black silk PLA, 100% infill, 0,08 layer (0.25 nozzle is necessary)

  • Fuel_tank_blue -  1 piece, blue silk PLA, 100% infill, 0,08 layer (0.25 nozzle is necessary)

  • Fuel_tank_bottom_cap -  1 piece, red silk PLA, 100% infill, 0,15 layer

  • L_fuel_tank_rubber  -  1 piece, black matte PLA / TPU, 100% infill, 0,15 layer

  • R_fuel_tank_rubber  -  1 piece, black matte PLA / TPU, 100% infill, 0,15 layer

  • Fuel_tank_insert  -  2 pcs, silver / chrome PLA, 100% infill, 0,15 layer

  • Fuel_tank_rear_holder  -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Seat_holder  -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Fuel_cap  -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

Fuel_tank_red/black/yellow/blue is necessary import into slicer together = multicolor print = MMU unit or AMS is required.

The following settings worked well for me when printing the fuel tank:

  • 1st layer 0.12

  • layers 0.08

  • infill 100%

  • gap above supports in Z axis 0.12

Assembly instruction:

  1. From the bottom of the tank, glue the Fuel_tank_bottom_cap. This will cover the hole in the tank, intended for the printing supports.

  2. Glue the R_fuel_tank_rubber and L_fuel_tank_rubber.

  3. Mount the tank on the motorcycle. At the back, use the Fuel_tank_rear_holder and the Seat_holder. Tighten everything with the M2.5-15 screw and nut.

  4. At the front, insert the Fuel_tank_inserts under the tank holders and screw them with the M2.5-8 screws.

  5. Put the Fuel_cap on and screw the M2.5-5 and M1.4-7 screw + nut. 

21.HANDLEBAR LEVERS

Printing instructions:

  • Decompressor_lever_body -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Decompressor_lever -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Lever_clamp -  2 pcs, silver / chrome PLA, 100% infill, 0,15 layer

  • Throttle_lever -  2 pcs, black silk PLA, 100% infill, 0,15 layer

  • Throttle_lever_body -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

  • Throttle_lever_cap -  1 piece, silver / chrome PLA, 100% infill, 0,15 layer

Assembly instruction:

  1. Once printed, set the parts aside and continue printing the handlebar parts.

 

22.HANDLEBAR

Printing instructions:

  • Handlebar -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Lever_sleeve -  2 pcs, silver / chrome PLA, 100% infill, 0,15 layer

  • Lever_guide -  2 pcs, silver / chrome PLA, 100% infill, 0,15 layer

  • Lever -  2 pcs, silver / chrome PLA, 100% infill, 0,15 layer

  • Handlebar_rubber -  2 pcs, black matte PLA / TPU, 100% infill, 0,15 layer

Assembly instruction:

  1. Slide 2x Lever_clamp onto the handlebar and rotate them to the correct positions according to the holes in the handlebar.

  2. Install Throttle_lever_body + 2x Throttle_lever and close everything with Throttle_lever_cap. Screw in the M1.6-8 screw.

  3. Install Decompressor_lever_body and screw the M1.6-5 screw.

  4. Install Decomressor_lever and secure it with the M1.6-3 screw.

  5. Glue 2pcs Handlebar_rubber onto the Handlebar. Align the ends with the end of the handlebar.

  6. Glue the Lever_guides into the handlebar.

  7. Slide the Lever_sleeves, insert the Levers and connect them together with the M1.6-6 screws and nuts.

  8. Check that all levers are movable.

23.SEAT

Printing instructions:

  • Seat_frame -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Seat_holder -  1 piece, black silk PLA, 100% infill, 0,15 layer

  • Seat_insert -  3 pcs, black silk PLA, 100% infill, 0,15 layer

  • Seat_rivet -  2 pcs, silver / chrome PLA, 100% infill, 0,15 layer

  • Seat_leather -  1 piece, black / brown matte PLA, 100% infill, 0,15 layer

  • Spring_tool -  1 piece, PLA, 8% infill, 0,15 layer

Assembly instruction:

  1. Use Spring_tool to create 2 springs from ø1mm wire.

  2. Hang Seat_holder into Seat_frame.

  3. Glue 12 pcs of ø1mm wire into the frame to creating "springs" of the seat

  4. Screw the springs to Seat frame using M2-5 screws with nuts.

  5. Insert Seat_insert into Seat_holder and screw with M2.5-18 screw.

  6. Insert 2 pcs of Seat_insert between springs and frame.

  7. Insert M3-63 threaded rod and secure nuts with M3 nuts.

  8. Glue Seat_rivets into recesses in Seat_leather and place Seat_leather on Seat_frame.

 

For even better results, I recommend making the cable lines from thin electrical wires.
If you've made it this far, then congratulations, because you've just finished building and can look forward to a complete motorcycle.


I hope you enjoyed the build. 

Now you can look forward to the next motorcycle I'm working on - a 1932 Rudge-Withworth 500 special.

Some photos from building are here: Rudge-Withworth 500 Special 1931 – jawarmaniak – album on Rajče

Bill of material:

  • Screw M1.4-2 - 2x

  • Screw M1.4-3 - 4x

  • Screw M1.4-5 - 2x

  • Screw M1.4-7 - 1x

  • Screw M1.4-10 - 2x

  • Screw M1.6-3 - 1x

  • Screw M1.6-4 - 12x

  • Screw M1.6-5 - 11x

  • Screw M1.6-6 - 5x

  • Screw M1.6-8 - 1x

  • Screw M2-4 - 8x

  • Screw M2-5 - 12x

  • Screw M2-10 - 1x

  • Screw M2-20 - 1x

  • Screw M2.5-4 - 1x

  • Screw M2.5-5 - 1x

  • Screw M2.5-6 - 5x

  • Screw M2.5-8 - 2x

  • Screw M2.5-10 - 4x

  • Screw M2.5-14 - 1x

  • Screw M2.5-15 - 1x

  • Screw M2.5-18 - 1x

  • Screw M2.5-20 - 1x

  • Screw M2.5-22 - 10x

  • Screw M3-10 - 1x

  • Screw M3-15 - 4x

  • Screw M3-16 - 4x

  • Screw M3-18 - 9x

  • Screw M3-40 - 1x

  • Screw M5-5 - 1x

  • Nut M1.4 - 3x

  • Nut M1.6 - 10x

  • Nut M2 - 9x

  • Nut M2.5 - 5x

  • Nut M3 - 36x

  • Nut M4 - 2x

  • Washer M3 - 20x

  • Washer M4 - 2x

  • Threaded rod M2-8 - 4x (or screw M2-10 -4x)

  • Threaded rod M2-8 - 1x

  • Threaded rod M2-20 - 1x

  • Threaded rod M3-20 - 3x

  • Threaded rod M3-24 - 1x

  • Threaded rod M3-26 - 1x

  • Threaded rod M3-32 - 3x

  • Threaded rod M3-50 - 1x

  • Threaded rod M3-52 - 1x

  • Threaded rod M3-60 - 4x

  • Threaded rod M3-62 - 1x

  • Threaded rod M3-63 - 1x

  • Threaded rod M3-70 - 1x

  • Threaded rod M3-72 - 1x

  • Threaded rod M3-73 - 1x

  • Bearing ball ø2 - 80x

  • Super glue

  • Tension spring 6/0.5-41.5 (or simmilar dimensions; avaliable here https://www.mateza.cz/e-shop/pruzina-vinuta-tazna-s-oky-d-d-6-0-0-55-mm-l-41-40-mm ) - 2x

  • Compression spring 7.3/0.9-10.8 (or simmilar dimensions; avaliable here Pružina vinutá - tlačná - D/d = 7.3/0.9 mm L=10.8 mm - ocel | Mateza.cz ) - 1x

  • wire ø1-38 - 2x

  • wire ø1-63 - 1x

  • wire ø1-75 - 84x

  • wire ~ø1-150 - 1x (for brake pedal rod)

  • wire ø1-200 - 2x

  • Ball bearing 683ZZ - 1x

  • Ball bearing 686 ZZ (6x13x5) - 3x

  • Ball bearing 688ZZ - 1x

  • M4 thread cutting eye

OPTIONALLY

  • Bearing roller 2x6.3 - 14x

  • Ball bearing 683ZZ - 1x

  • Ceedle cage - K7x10x10 - 1x

  • Eletric wires ø0.5-1mm

Tags

bikemotorcycleveteran300dkw

Model origin

The author marked this model as their own original creation.

License