Project JAWA-ČZ KÝVAČKA 250/353.02 - PART No.10 - LAST ONE :)

Finally I bring you the last part of my built. After this part you will have a complete 3D model of the SOLO bike. 

Of course, if you also want to own a sidecar or a winter fairing, you need to continue to persevere in the construction

Hope the 9th part was fun for you :)

Project JAWA-ČZ KÝVAČKA 250/353.02 - PART No.9 - SIDE BOXES + FOOTRESTS od autora jawarmaniak | Stáhněte si zdarma STL model | Printables.com

As usual the model part consist a big parts but the very small also so pay attention to the description and attached pictures. As usual be extremely careful during the assembly itself and work slowly and cautiously.
If you manage to damage or break some part despite being extra careful you should "weld" it with a soldering gun rather than gluing it with super glue.

For today I prepared to you the front mudguard, seat, exhaust pipes and some small parts. Before each glue try to assembly all parts together and make sure that all parts fit.

If you will need more pictures for better understanding, you can see here:

https://www.rajce.idnes.cz/jawarmaniak/album/jawa-tisk

at first we started with the switch box

Printing instruction:

• switch_box_cover - 1 piece, dark brown PLA, 100% infill, 0.15-0.2 layer.
• switch_knob - 1 piece, dark brown PLA, 100% infill, 0.15-0.2 layer.
• switch_box_bottom_cover - 1 piece, red PLA, 100% infill, 0.15-0.2 layer.
• switch_box_connector - 8 pcs, brass/gold PLA, 100% infill, 0.15-0.2 layer.
• indicator_cover - 1 piece, crystal clear / transparent yellow PLA, 100% infill, 0.15-0.2 layer.
• switch_box_sealing - 1 piece, black PLA, 100% infill, 0.15-0.2 layer.
• ammeter_body - 1 piece, grey PLA, 100% infill, 0.15-0.2 layer.
• ammeter_dial - 1 piece, black PLA, 100% infill, 0.15-0.2 layer.
• dial_hand - 1 piece, white PLA, 100% infill, 0.15-0.2 layer.
• ammeter_glass - 1 piece, transparent PLA, 100% infill, 0.15-0.2 layer - or - plastic foil

Assembly instruction:

• Glue the dial_hand into the center of the ammeter_dial 

• Glue the printed ammeter_glass or the piece of the transparent plastic foil into the ammeter_body
• Install the ammeter dial assembly into ammeter_body. Be careful about the correct position. See the picture.
• Glue the indicator_cover, switch_knob  and the ammeter assembly into the switch_box_cover.
• Glue 8 pcs of the switch_box_connector into the switch_box_bottom_cover.

• Screw the switch box cover assembly and the switch box bottom cover together by 3 pcs of the M1.2-7 screws.
• Glue the switch_box_sealing on the tank, install switch box and screw it by 3 pcs of M1.2-12 screws.

at second we can make the speedometer

Printing instruction:

• speedometer_dial - 1 piece, black PLA, 100% infill, 0.15-0.2 layer.
• speedometer_hand - 1 piece, white PLA, 100% infill, 0.15-0.2 layer.
• speedometer - 1 piece, grey PLA, 100% infill, 0.15-0.2 layer.
• speedometer_body - 1 piece, black PLA, 100% infill, 0.15-0.2 layer.
• light_guide - 1 piece, crystal clear / transparent yellow PLA, 100% infill, 0.15-0.2 layer.
• speedometer_glass - 1 piece, transparent PLA, 100% infill, 0.15-0.2 layer - or - plastic foil
• speedometer_ring - 1 piece, chrome PLA, 100% infill, 0.15-0.2 layer.
• speedometer_sealing - 1 piece, black PLA, 100% infill, 0.15-0.2 layer - or rubber O-ring.
• speedometer_shim - 2 pcs, grey PLA, 100% infill, 0.15-0.2 layer.
• speedometer_holder - 1 piece, grey PLA, 100% infill, 0.15-0.2 layer.

Assembly instruction:

• Create an M5 thread on the speedometer. After that glue it into the speedometer_body.

• Glue M1-3 and M1.4-3 screws into the speedometer_dial from bottom side. On the thread from bottom side slide one piece of the speedometer_shim and screw low M5 nut.
• Glue speedometer_hand on the top of the 1.4-3 screw according picture.

• Glue the dial assembly into the body assembly.
• insert light_guide.
• Glue the speedometer_glass or a piece of the transparent plastic foil into the speedometer_ring.
• Glue the ring assembly on the top of speedometer assembly.
• Insert speedometer_sealing from bottom side. You can also use O-ring insted of the printed part.
• This assembly insert from top side into the top cover of the headlight.
• From inside insert the speedometer_holder and speedometer_shim. 
• Screw second low M5 nut.

at third we can make the fuel petcock

Printing instruction:

• petcock_rod - 1 piece, grey PLA, 100% infill, 0.15-0.2 layer.
• petcock_cover - 1 piece, chrome PLA, 100% infill, 0.15-0.2 layer.
• petcock_cone - 1 piece, brass / gold PLA, 100% infill, 0.15-0.2 layer.
• petcock_body - 1 piece, grey PLA, 100% infill, 0.15-0.2 layer.

Assembly instruction:

• Glue petcock_rod into hole in the petcock_cone.
• Slide petcock_cone into the petcock_body.
• Glue petcock_cover on the free end of the petcock_cone. The cone should move.
• Whole assembly glue into the hole in the fuel tank.

at fourth we can make the fuel petcock

Printing instruction:

• taillight - 1 piece, grey PLA, 100% infill, 0.15-0.2 layer.
• taillight_connector1 - 1 piece, brass / gold PLA, 100% infill, 0.15-0.2 layer.
• taillight_connector2 - 1 piece, brass / gold PLA, 100% infill, 0.15-0.2 layer.
• taillight_connector3 - 1 piece, brass / gold PLA, 100% infill, 0.15-0.2 layer.
• taillight_connector4 - 1 piece, brass / gold PLA, 100% infill, 0.15-0.2 layer.
• taillight_isolation - 2 pcs, dark brown PLA, 100% infill, 0.15-0.2 layer.
• taillight_glass - 1 piece, crystal clear PLA, 100% infill, 0.15-0.2 layer.
• taillight_cover - 1 piece, red PLA, 100% infill, 0.15-0.2 layer.
• taillight_rubber - 1 piece, black PLA, 100% infill, 0.15-0.2 layer.

Assembly instruction:

• Glue together taillight, taillight_connector1-4 and taillight_isolation into one assembly.
• Glue the taillight_glass into the taillight_cover.

• Now is necessay to drill hole 1.6mm according taillight assembly. I forgot it at biggining. I am sorry for that - my mistake. If you do not have so small drill, you can make the hole by hot piece of wire or by the hot needle. After it you can screw the taillight_rubber and glued taillight assembly by M1.6-5 screw with nut.

• Install taillight cover assembly and screw it by M2-3 screw on the top side.

at fifth we can make the rear license plate

Printing instruction:

• rear_license_plate - 1 piece, white / black PLA, 100% infill, 0.15 layer.
• rear_license_plate_holder - 1 piece, grey PLA, 100% infill, 0.15-0.2 layer.

During printing of the rear licence plate you have to start with white PLA and at the height of the 1mm you must put the break and change color to black one!

Assembly instruction:

• Screw the rear_license_plate_holder into the rear fender by M1.6-3 screw with nut.

• Screw the rear_license_plate by M1.6-5, M1.6-3 screws with nuts.

at sixth we can make the fuel cap

Printing instruction:

• fuel_cap - 1 piece, chrome PLA, 100% infill, 0.15 layer.
• fuel_cap_spring - 1 piece, chrome PLA, 100% infill, 0.15 layer.
• fuel_cap_sealing - 1 piece, black PLA / TPU, 100% infill, 0.15-0.2 layer.

Assembly instruction:

• Insert the fuel_cap_sealing into the fuel_cap.
• Insert fuel_cap_spring and weld it by soldering gun.

• The fuel tap assembly should mounted into the fuel tank by hand. Glue is not necessary.

at seventh we can make the air filter

Printing instruction:

• air_filter_body - 1 piece, grey PLA, 100% infill, 0.15-0.2 layer.
• air_filter_grille - 1 piece, chrome PLA, 100% infill, 0.15-0.2 layer. - After printing do not waste the support from this part, You will need it!
• choke - 1 piece, chrome PLA, 100% infill, 0.15-0.2 layer.

Assembly instruction:

• Assembly together the air_filter_grille and the choke. From inside melt the end of the central pin by soldering gun. The choke should stay movable.

• Glue the support from the air_filter_grille into air_filter_body. You can paint it by black pen.

• Glue grille assembly and filter body assembly together
• Insert M1.4-5 screw into air filter body.

Printing instruction:

• carburetor_body - 1 piece, grey PLA, 100% infill, 0.15-0.2 layer.
• carburetor_body_cap - 1 piece, grey PLA, 100% infill, 0.15 layer.
• carburetor_body_nut - 1 piece, chrome PLA, 100% infill, 0.15-0.2 layer.
• float_chamber - 1 piece, grey PLA, 100% infill, 0.15-0.2 layer.
• float_chamber_cap - 1 piece, grey PLA, 100% infill, 0.15-0.2 layer.
• float_pin - 1 piece, chrome PLA, 100% infill, 0.15-0.2 layer.
• float_chamber_intake - 1 piece, brass / gold PLA, 100% infill, 0.15 layer.
• carburetor_bottom_plug - 1 piece, chrome PLA, 100% infill, 0.15-0.2 layer.
• carburetor_flange - 1 piece, grey PLA, 100% infill, 0.15-0.2 layer.
• carburetor_sleeve - 1 piece, grey PLA, 100% infill, 0.15 layer.

Assembly instruction:

• Screw one M1.4-3 and one M1.4-5 screw with nut into carburetor_body.

• Glue together carburetor_body, carburetor_body_nut, float_chamber and the carburetor_bottom_plug.

• Glue together float_chamber_cap, float_pin and the float_chamber_intake.
• Glue the carburetor_body_cap.
• Screw the whole float chamber cap on the float_chamber by 2 screws M1.2-3
• On the carburetor body assembly insert carburetor_sleeve with M1.4-5 screw.

• install the carburetor_flange on the engine. For it you need 2x screw M2.5-5.
• Install The air filter (from last step) on the carburetor, whole assembly slide on the carburetor_flange and tight the carburetor_sleeve.

And as a last part we can make the front bowden holder

Printing instruction:

• Front_bowden_holder - 1 piece, red PLA, 100% infill, 0.15-0.2 layer.

Assembly instruction:

• Screw the holder to the frame by 2 M 1.4-3 screws

Now your bike is complete. You can use black isolation from 1,5mm electric wires (i.e. CYSY or CYKY) for simulation of the bowdens and the fuel pipe. It's a detail that makes the whole model even better. 

AND… That's it for now.

Bill of material:

• 1x nut M1.4
• 4x nut M1.6
• 2x LOW nut M5 DIN 439B
• 1x screw M1-3 mm or piece of the wire diameter 1mm
• 2x screw M1.2-3 mm
• 3x screw M1.2-7 mm
• 3x screw M1.2-12 mm
• 4x screw M1.4-3 mm
• 3x screw M1.4-5 mm
• 2x screw M1.6-3 mm
• 2x screw M1.6-5 mm
• 1x screw M2-3 mm
• 2x screw M2.5-5 mm
• superglue

OPTIONALLY 

• isolation from electric wires 1.5mm^2

I hope you had fun during building and everything went smoothly.

And.. what next? Well you can see on the pictures below. There are some pictures of the sidecar Velorex 560 which you can look forward to.. 

https://www.printables.com/cs/model/861669-sidecar-velorex-560