This video provides a detailed walkthrough of a small, custom CNC machining project. The objective is to modify an aftermarket aluminum handlebar mount for a friend's Honda Ruckus motorcycle by adding a recessed pocket and a tapped hole for a tachometer bracket. The process is documented from start to finish, beginning with the CAD design and CAM programming in Autodesk Fusion 360. The video then moves to the hands-on machining, where a Miltronics tool room mill is set up and a test piece is run. After discovering a dimensional error in the initial test, the speaker demonstrates how to quickly correct the design in Fusion 360 and regenerate the program before successfully machining the final part. The project highlights the precision and efficiency of using modern CNC tools for one-off custom jobs.
Machining a Custom Tachometer Mount for a Honda Ruckus
0:00:15 Project Introduction: The goal is to mill a recessed pocket and drill and tap a hole into an aftermarket handlebar mount for a friend's Honda Ruckus. This modification will allow a tachometer bracket to be installed without interfering with the top handlebar clamp.
0:02:40 CAD/CAM Design in Fusion 360: The creator details the process of modeling the required modification in Fusion 360. He demonstrates creating the sketches, extruding the pocket, and programming the toolpaths for four different tools: a 1/4" endmill, a chamfer tool, a #7 drill, and a 1/4-20 tap.
0:11:07 CNC Mill Setup: The Miltronics tool room mill is prepared for the job. This involves installing and tramming (precisely aligning) the machine vise to ensure accuracy.
0:16:47 Probing and Test Piece: Before machining the actual part, a scrap piece of aluminum is used as a test block. A Renishaw probe is used to set the work coordinates, a process briefly delayed by the need to change the probe's batteries.
0:28:23 Initial Test Fails: The first test cut is completed, but the milled pocket is slightly too narrow for the tachometer bracket to fit. This step demonstrates the value of running a test piece to verify a program.
0:29:01 Correcting the Program: The creator returns to Fusion 360 and easily adjusts the pocket width from .781" to .855". He then regenerates the toolpaths and outputs a new G-code file for the machine.
0:31:47 Successful Test and Refinement: The corrected program is run on the test block. The bracket and bolt now fit perfectly. The creator runs the program a second time to refine speeds and coolant usage before moving to the final workpiece.
0:41:31 Machining the Final Part: The actual handlebar mount is clamped in the vise. The probe is used to find the precise center and top surface of the part, and the finalized CNC program is executed.
0:47:43 Project Completion and Final Result: The machining is completed in approximately three minutes. The final part is shown with the bracket perfectly seated in the recessed pocket, resulting in a clean, professional-quality modification.