The challenge
The X1 uses a motorcycle engine, and we wanted to improve its starting system by driving it through a reduction gearbox. The adapter had to bolt onto the original engine casting, which is full of complex curved surfaces and has no drawings available, while holding the starter motor and gears in exact alignment. Measuring it by hand would have been slow and risky.
Requirements
- A precise fit to the original engine casting
- Correct gear reduction and alignment between the starter motor and the engine
- Bolt-on installation with no modification to the engine
- A clean, branded finish worthy of a race car
- Supplied as a complete kit
Our approach
We worked from a 3D scan of the engine, which captured the casting surfaces and mounting points accurately. The adapter housing, reduction gear and cover were designed in CAD directly against the scan data, so every face, bolt hole and gear centre lined up with the real engine.
The parts were then machined through our partner network and packaged as a bolt-on kit, with a Hyper branded cover to finish it off.
Results
Designing from scan data is how we take on parts that have to fit something without drawings, such as an existing machine, vehicle or casting. It removes the guesswork and the expensive second attempt.
Gallery
