The Search for Fuel Economy

Pages from a Designers' Notebook

Freedom Machine
The goal: 100 mpg at 70 mph, into a 30 mph headwind, with four bags of groceries.
Chap. 33: New gears for the Helix

(The impossible just got possible)

This is what the Helix final drive looks like
Jan Vos of Belgium is well known in fuel economy circles as the machinist who made a new gear set for his Burgman to slow his engine down. He presented his work on ecomodder .

My Helix Streamliner project is stalled out because I need new gears. I don't know how to make them because I am not a machinist.

You can imagine my delight a couple of weeks ago when I received this E mail:

What a gear cutter looks like
Hallo Craig.

I still follow your progess with the Honda Helix. The looks getter better with latest modifications.I think you need for improvement of the MPG a higher gear ratio at least 20% higher than you are using now.I am willing to make that for you against a cost that you cannot refuge.I made a big jump in MPG with my Suzuki Burgman when using the new ratio.It will be spur gears, that is the only type I can make.What do you think?

regards

Jan Vos
What did I think? "Its a miracle" is what I thought! Just how many people are there in world who can and are willing to do this? Jan and I exchanged E mails. All I had to do was send him a set of gears from a Helix and he would do the rest.

I knew where there was a set of gears.

My old friend, Ernie Buckler in Spokane, Washington is an eclectic fan of FF (feet forward) machines. He once mentioned that he had a spare trashed Helix engine. But the drive train was good.

He offered to send it to Belgium. It got there in 3 days! As I post this page, Jan is cutting new gears to slow my Helix engine down 20%.

Feb 19, 2010: Jan is making gears faster than I can put them up on my web page!

Wow!

As of Feb 19, 2010
Feb 24, 2010
Craig.

I received the gears today from the wire EDM shop. End of this week the gears go to a shop for hardening. Typically this takes a week and a half.

When they are back they can be finished in one day.

regards

Jan
Page posted Feb 17, 2010

Updated Feb 24, 2010

Chap. 3: Road Testing the Long Tail Mar 28, 08
Chap. 1: Streamlining Saves Fuel Feb 20, 08
Chap.2: CAD Streamlined Body Mar 8, 08
Chap. 4: Planking with Foam Apl. 5, 09
Chap. 5: More Wind Testing Apl. 7, 08
Chap. 6: The Final Shape Apl. 17, 08
Chap. 7: Decisions about Details May 10, 08
Page 8: Making the Center Bulkhead June 1, 08
Chap. 9: Rear Bulkhead and Truck bed June 8, 08
Chap. 10: Finish Rear and go for ride June 17, 08

If you have not yet watched my DVD, How they Got 470 mpg it is time to get it for the basic foundation for what we are doing here

Chap. 11: Finish the Tail June 29, 08
Chap. 12: Heading for Ohio, July 13-23, 08
Introduction to Fuel Economy
Chap. 13: Riding in the Midwest July 24, 08
Chap. 14: Vintage Days Ohio, July 25-7, 08
Chap. 15: Summary to date Aug 12, 08
Chap. 16: Adding Weight to the Front Sep. 1, 08
Chap. 17: Truth and Motorcycle Design Sep 4, 08
Chap. 18: Where should the weight be? Sep 25, 08
Chapter 19: Finishing the Streamlining Oct 14, 08
Chapter 20: Streamlining the Handlebars Nov 4, 08
Chapter 21: Unexpected Problems Nov 11, 08
Chapter 23: Getting my feet in and out Dec 19, 08
Chapter 22: Streamlining is working Nov 25, 08
Chapter 24: Streamlining is beginning to work! Jan 1, 09
Chapter 25: Tuft Testing Mar 2, 2009
Chapter 26: Starting Over April 9, 09
Chapter 27: More Ideas for Starting over April 20, 09
Chapter 28: Show time! Aug 1, 2009
Chapter 29: Getting the big parts right Dec 10, 2009
Chapter 30: First evaluation from an outsider
Chapter 31: Visit with Allert Jacobs
Chapter 32:
Chapter 33:

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