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  1. #1
    e.f.f.e.c.t smoothoperatr
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    Caution;  Merge;  Workers Ahead! tech? making a integrated stem

    yozz
    cause im into this stuff, i want to make a integrated stem for my 06 boxxer. i dont want any comments of "just buy one" cause its good to get the hands dirty and do it yourself. me and my friends got the machines, bridgeport mills and lathes, couple questions. what kind of material ( alluminum). is it all 6061 alluminum? if not, what kind. any other tips, other then to check 4 times, then cut
    thanks

  2. #2
    mtbr member
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    I am also inerested as I want to make a new top crown with intergrated stem for my 01 monster t
    Quote Originally Posted by Qatarbhoy
    I have to ask for them to do a "Number two" on my head

  3. #3
    Dr. Bike
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    Typically they use 6061 aluminum in those applications. Not that you would need to know this for a stem but a welder told me 6061 is much easier to weld than 7000 series aluminum.
    I agree with you about being fun to make things yourself. I'm a machinist and have made all sorts of things for my bikes.
    If you make something idiot proof, someone will make a better idiot !

  4. #4
    e.f.f.e.c.t smoothoperatr
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    Quote Originally Posted by david101372
    Typically they use 6061 aluminum in those applications. Not that you would need to know this for a stem but a welder told me 6061 is much easier to weld than 7000 series aluminum.
    I agree with you about being fun to make things yourself. I'm a machinist and have made all sorts of things for my bikes.

    i wont be welding, that would be to sketchy for me for a stem

    im milling it from a block

  5. #5
    pwn3rator
    Reputation: scabrider's Avatar
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    go with 7000 sieries aluminum (7075 is best) if you wont be welding, it will hold up better over time and is much harder than 6000 sieries. when you make the part for your bars to go through, drill the hole the same dia. as the bars and then cut that sectoin in half, giving you the bar clamp. the drill and tap yor bolt holes and finally mill about .100 to .150 off each side on the inside (the side that the bars touch) so you can clamp the bars firmly. also i would go with a sinlge piece like the marz. integrated stem instead of the two piece ones e.13 makes for boxxers. that's about it, anymore explanation would require pictures. i could make you one, $83.00/hour is the shop rate...
    [SIZE=-4]SOCAL UNION REPREZENT[/SIZE]
    Quote Originally Posted by JBsoxB
    does it still qualify as a mountainbike?
    Quote Originally Posted by kidwoo
    I've beat beer cans on my limp pee pee.

  6. #6
    e.f.f.e.c.t smoothoperatr
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    Quote Originally Posted by scabrider
    go with 7000 sieries aluminum (7075 is best) if you wont be welding, it will hold up better over time and is much harder than 6000 sieries. when you make the part for your bars to go through, drill the hole the same dia. as the bars and then cut that sectoin in half, giving you the bar clamp. the drill and tap yor bolt holes and finally mill about .100 to .150 off each side on the inside (the side that the bars touch) so you can clamp the bars firmly. also i would go with a sinlge piece like the marz. integrated stem instead of the two piece ones e.13 makes for boxxers. that's about it, anymore explanation would require pictures. i could make you one, $83.00/hour is the shop rate...

    yeah im gunnu make a single peiced one
    i was thinkin of the same process with making the bar clamp, good stuff, 15 hundreths of an inch?

  7. #7
    pwn3rator
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    150 thousanths...
    [SIZE=-4]SOCAL UNION REPREZENT[/SIZE]
    Quote Originally Posted by JBsoxB
    does it still qualify as a mountainbike?
    Quote Originally Posted by kidwoo
    I've beat beer cans on my limp pee pee.

  8. #8
    e.f.f.e.c.t smoothoperatr
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    Quote Originally Posted by scabrider
    150 thousanths...

    gah thats what i thougth, i suck with decimels

  9. #9
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    i dont think scab rider know wat hes talking about
    i designed this one. u dont kneed and tools to take out the bars
    IS THIS SOMETHING YOU CAN SHARE WITH THE REST OF US AMAZING LARRY ?!?!?!

    aircooled VW FTW

  10. #10
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    Quote Originally Posted by Amazing Larry104
    i dont think scab rider know wat hes talking about
    i designed this one. u dont kneed and tools to take out the bars
    And you do? Wtf is that.

  11. #11
    Freeride / Downhill Dude
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    ROFL surely the bars are just going to spin like crazy in that thing.

    Also, what's the point - not many people do trailside handlebar swaps and even if they wanted to - carry a multi-tool?!?

    Sorry, don't mean to sound demeaning.
    I'm on the Twitter.

  12. #12
    Pro Crastinator
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    you 2 are obviously dorks, the stem above is as real as they come. larry made me one about a month ago and the thing works flawless.....


  13. #13
    Freeride / Downhill Dude
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    Quote Originally Posted by .WestCoastHucker.
    you 2 are obviously dorks, the stem above is as real as they come. larry made me one about a month ago and the thing works flawless.....
    lol, I'm not a dork - can't vouch for Kjcorley

    Pretty surprised, want to see a pic of this! Cummon the pic's hardly a precise CAD.

    What was the reason for creating a tooless stem anyway?
    I'm on the Twitter.

  14. #14
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    Quote Originally Posted by Ace1
    Cummon the pic's hardly a precise CAD.
    My thoughts exactly.

    If your gonna try and convince me that you made it or that you could make it, at least upload a decent cad drawing and rendering not a dinky picture made in paint. Not to be hatin or anything, just don't go dissing what scab rider is saying (he seems to know what he is talking about) and then try and justify your special stem with a drawing that looks like a joke. If it's real though, I'd love to see a picture.

  15. #15
    Pro Crastinator
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    those were the prototype spy pics.......


  16. #16
    e.f.f.e.c.t smoothoperatr
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    amazinglarry is in trouble, he was not supposed to release those until the end of this season someones getting fired.

  17. #17
    notabouttoseeyourlight
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    ......
    cycle tracks will abound in utopia.

  18. #18
    Equal opportunity meanie
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    I milled out an integrated stem for my '05 Boxxer a while back (no longer have the fork but kept the stem). It came out very well and lasted much longer than I thought it would and didn't fail. If you use pre-heat treated 6000 series you should be fine. I believe I used 6061-T6.

    The hardest part I ran into was making the cut for the handlebars. Since we didn't have any stock sitting around that was thick enough and wide enough to cut it out of one piece I had to make two, cut the bolt holes and threads, then did a 1.25" endmill plunge through the stem with it already bolted together in the vice with a 1/10" spacer between the pieces for the offset. The problem that comes from this is that you will probably not have an endmill that is long enough to go all the way through with out hitting the collet, so you may have to run it a 1/4" - 1/2" out. Conveniently enough though, handlebar diameters are exactly the same as your 1" and 1.25" endmills so you won't need a bore tool.

    I'll find some pics of it soon and feel free to PM me if you want any other details.

    Scabrider, 150 thous is the same as 15 hundredths....I wouldn't be paying you any $83/hour for machine work....

  19. #19
    Glad to Be Alive
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    Quote Originally Posted by Amazing Larry104
    i dont think scab rider know wat hes talking about
    URL]
    no....he does, been milling stuff a lot
    the trick is ENJOYING YOUR LIFE EACH DAY, don't waste them away wishing for better days

  20. #20
    mtbr member
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    Quote Originally Posted by SHIVER ME TIMBERS
    no....he does, been milling stuff a lot
    so have i
    IS THIS SOMETHING YOU CAN SHARE WITH THE REST OF US AMAZING LARRY ?!?!?!

    aircooled VW FTW

  21. #21
    Oh, So Interesting!
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    Quote Originally Posted by scabrider
    go with 7000 sieries aluminum (7075 is best)...
    Yes, its about %75 stronger for what you'll use it for over 6061. 6061 is NOT a high stregnth alloy, if you copied current integrated stem designs made from 7000 series w/6061, it would probably fail.

    You might want to check out Romic's top crown/stem design, I have it for my '06 Boxxer, but don't use the stem because it's not exactly what I want. I was thinking about making a stem to fit my Romic crown as well... I would definately very closely copy another stem design unless you want to use engineering software to determine stresses in your design.
    .




    Strava: turn off your dork logger when you're not on sanctioned trails.

  22. #22
    Glad to Be Alive
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    Quote Originally Posted by Amazing Larry104
    so have i
    so you bash him and don't even know him or what he does.....does that make him bad???why did you hate him????
    the trick is ENJOYING YOUR LIFE EACH DAY, don't waste them away wishing for better days

  23. #23
    SNOWRIDER
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    Good job! Custom stuff rocks

    Good luck on your stem, be sure to post up pics when you are done.
    I too am running a Boxxer and have been thinking about integrated stems.

    alot of you may remember my chain guide but here are the pics again
    Attached Images Attached Images
    "If you don't go [skibiking] this year, you'll be at least one year older when you do." ~ Warren Miller
    (Check out the 'IMPACT' video for some skibike footage)

  24. #24
    moaaar shimz
    Reputation: tacubaya's Avatar
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    Quote Originally Posted by Amazing Larry104
    i dont think scab rider know wat hes talking about
    i designed this one. u dont kneed and tools to take out the bars
    Lemme se If I get It, if you have some handlebar in that stem and the stem keeps it tight, how are you going to pusth the top part so it opens? You would have to slide the handlebar out if its flat, because I dont see another way.

    Also with a good crash the bottom part of the locking would just shatter.

  25. #25
    SNOWRIDER
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    Quote Originally Posted by tacubaya
    Lemme se If I get It, if you have some handlebar in that stem and the stem keeps it tight, how are you going to pusth the top part so it opens? You would have to slide the handlebar out if its flat, because I dont see another way.

    Also with a good crash the bottom part of the locking would just shatter.
    I don't think I would trust that either........

    [SIZE="5"]I want pics[/SIZE]
    "If you don't go [skibiking] this year, you'll be at least one year older when you do." ~ Warren Miller
    (Check out the 'IMPACT' video for some skibike footage)

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