Honda CBR 600cc 10x6 Aluminum Airboat Build

Airboats with smaller powerplants.
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Deano
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Deano » Sun Oct 22, 2017 9:05 am

Just a couple passing comments that I hope will help.

First off in my opinion, Russ' comments about steel vs. aluminum is that not only are his observations correct; but correct to
such a magnitude and extent, that I wouldn't miss a beat by considering the other. Realistically, anything you use will be very close to the same weight in the end, largely because of the need to increase the thickness of the aluminum to offset its lack of strength that Russ eluded to. From a budget standpoint, steel is very difficult to beat when that is part of the consideration.

While it is true that aluminum will last longer in a salt environment and give less grief over time in that situation, the build you propose does not look like it's going to spend a lot of time offshore. :D You can also fully expect that properly coated steel will easily last more than plenty long enough for you to get you to your next 'family necessitated upgrade', and shift your focus and resources toward that end. :)

The other thing is . . . I would not build the cage any smaller than need be in any case. You can always run a smaller prop in a bigger cage, you can never run a bigger prop in a smaller cage. :idea: While it may not be as important on a small hot rod as it is with something much bigger, the reality remains that for all out push, diameter trumps pitch when other things are equal. This is why you see helicopters with very long skinny blades instead of the short fat ones that we run out of necessity.

When you get that far, you will come to the realization that 72" is a VERY common size prop, and consequently a little easier to find due to the shear numbers of them around. It would be a shame that has happened many times before, to build the cage to fit a smaller prop and then find the deal of a lifetime on one that is just a little to big to use without having to regroup and start over, so to speak. It has already been shown that a 76" cage will fit a 72" prop rather nicely. 8)
"The suppression of uncomfortable ideas may be common in religion and politics,
but it is not the path to knowledge; it has no place in the endeavor of science."
- Carl Sagan

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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Fri Oct 27, 2017 9:35 pm

Thank you Russ and Deano, excellent information and input! I really appreciate it. I think steel is going to be the material of choice and I should take the cage as wide as I can and aim for a 72" prop.

After thinking about the fatigue strength of aluminum I added a couple more deck supports up front and under all of 1" angle deck supports I welded in a second piece of angle to get me a little more weldable surface to support the deck and associated stresses.

I ordered a gallon of steel flex 2000 super slick and white pigment and did some prep to get it ready for coating. I'm thinking ultimately the deck and rigging will be painted like a darker silver with blue seadek on the deck. That's the thought on overall look so far.

I did some clean up on the engine and pulled the carbs to clean them out so that it will be ready for its engine stand. Next step is to go pick up some metal and get started on the stand.

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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sun Nov 05, 2017 7:38 pm

Update. I got my order of 1gallon steelflex 2000 super slick with white pigment from fasco and I also opted to place an order for some of their #26 fairing compound. When I welded the center seam of the hull and and stringers to the hull I learned why it wasn’t welded. I got some warpage but was able to fair it all out nicely with the fairing compound after prepping the hull with aluminum brightener. That aluminum brightener does an amazing job cleaning aluminum. I wish I knew about it months ago.

I laid down four thin layers of the steelflex super slick and it is super slick. Love how the finish turned out. I used a squeegee and a roller but I finished each coat with the squeegee because it produces a super smooth surface compared to the roller.

That’s it for now. Need to get some metal for an engine stand.
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sun Nov 05, 2017 8:13 pm

Fairing and steelflex superslick
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Garrett314 » Mon Nov 06, 2017 6:50 pm

this is a great project, thanks for sharing. I am intrigued! :usa:
13'6 cottonmouth with poly, 520 gpu, 2 blade terminator

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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Thu Nov 23, 2017 2:32 pm

Happy Thanksgiving everyone. Thanks Garret! Yeah it’s a project that I am definitely enjoying and I’m glad to be able to share it.

I have made a little bit of progress. I cut all the aluminum decking to size with no measurement errors. Stripped all the old paint off the aluminum. The decking metal was from old carnival haunted houses so they had some ghosts and stuff painted on them that I didn’t care for even on the underside of the deck, bad vibe, so a little paint stripper and prayer took care of that. Think the boat it really starting to come together now. I am going to hold off on painting or riveting the decking until I get the engine and seat stand underway and I still need to pick up and cut holes for a couple 4”-6” round deck hatches. They will be back near the transom for access to the bilge pump, drain plug and the engine stand and cage bolts.

I picked up 24’ of 3/4” 1/16th wall square tubing and some 1 1/2” x 3/16” flat bar for mounting and bolting through. Still trying to work out the plan for the engine stand to accommodate sprockets, chain, pillow blocks, types of bearings, shaft diameter plus many other variables and making it all work together. The engine is a little awkward to work with.

What is the average depth of most pancak cages? 10” 12” 14”? I guess it varies with prop and adapter. If I can get away with 10” it would leave more working room for the engine stand.
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Wed Dec 13, 2017 9:58 pm

Managed to get the deck riveted down and picked up a couple 4” hatches for the back to access drain plug and bilge.

I am doing a 1 1/2” lip around the opening in the center of the hull with an alumnum lid. That way I can keep the leaves and junk out and have storage and if I need to put something bigger down there I can leave the lid off. I just built the 1 1/2” frame for the opening and a 1” angle frame to use for the lid. Need to complete the lid and bolt the frame down with stainless hardware.

The engine stand is under construction but I got to the point that I needed to order bearing, sprockets, shafts and the like for the mock up, so I did that. I’ll post pics of that as I make a little more progress.
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby mm22687 » Sun Dec 24, 2017 12:18 am

That lil boat has come a long way since I sold it. Love the ideas for it. Hope you turn that thing into a little ripper

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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Tue Dec 26, 2017 7:18 pm

Hey mm22687! Thanks, I hope it runs like a scalded cat when she is finished. I would love to know anything you know about the boat like when you owned it and sold it, any work that you may have done to it, what it came from and any other history out may know about the boat.

It’s been a great project.

I got all my bearings, shafts and sprockets in. I ordered a 16 tooth double chain coupling thinking the output sprocket on the engine was 16 tooth, turned out it is 15 tooth. So I miss counted teeth. Ordered a new 16 tooth sprocket for the engine and I got a 520 pitch instead of 530 pitch. So it’s a little narrow and allows more slop than I like in the double chain coupler. The right output sprocket should be in by Monday.

In the mean time i have been working on engine mounts.
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Tue Jan 09, 2018 7:00 pm

Since the last post I have made the front engine mounts and the mount for the 4 bolt flange bearing on the jack shaft. I haven’t welded everything solid yet because inevitably I will have to make some alterations and I want to make it easy on my self when it does happen.

Next I am going for the pillow block bearings and main shaft mounts followed by an idler sprocket, exhaust hangar, fuel tank , battery box, radiator mounts and plumbing, mounts for seat stand and supports for the pancake cage.
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby OneBFC » Wed Jan 10, 2018 8:47 am

Does your design account for the axial thrust load on the bearings at the propeller shaft?

In what I can see, it appears you have chosen a standard pillow block bearing for the propeller shaft.
Be sure it is rated for an axial load well in excess of the predicted thrust you intend to make.
-Russ
-----------------------------------
The only thing stopping you is FEAR
400+hp Ecotec, 12x7.6 DBDO, 80" 3B Maximus, 2.3 OX,85+mph, water = purely optional
Life begins at 2 BAR, Just a good ole boy

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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Fri Jan 12, 2018 10:56 pm

Yes it's close. I called around to a few sources and was advised that a boat of this hp would produce around 500lb of thrust or so peak. Each pillow block is good for 3600rpm and 300lb axial load so 600lb combined (as long as the load is balanced between the 2 bearings). So it's a little close but that's at peak thrust and I imagine they test the bearings at twice that so there is a little wiggle room. I'm hoping I will work out alright. The next step up to a higher axial load rated bearing was a $140 each so it's not out of the question but I want to see it run first.

The shaft is 1 1/4" and I got (2) 1 1/8" split ring shaft collars so I can cut a groove the width of the collar so it locks agains a shoulder as an extra stop in addition of o the set screws.

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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sat Feb 03, 2018 4:20 pm

Battery box built and idle adjustment mounted below it. Next I’m starting to think about a fuel tank, radiator mount and where the seat stand is going to mount.
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sun Feb 25, 2018 7:25 pm

Work has been busy so progress has been slower than I would like but it’s still coming along. I mocked up a fuel tank and took it to a local metal shop to have some aluminum broke for it. I welded some extra bracing into the bottom of the hull and I bolted and sealed the flang in place for the lid. Mounted the radiator and now I need to pick up some radiator hose for it and a new battery so I can crank it up.
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby AlaskanOutdoorsman » Mon Feb 26, 2018 3:03 am

Have you downloaded the engine powerband to see the HP at various RPM's? Your engine is 100.00 HP @ 12000 RPM with 62.76 Nm (46.3 ft.lbs) of torque @ 10500 RPM. What are you anticipating your cruising RPM/HP to be?

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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Mon Feb 26, 2018 4:42 pm

No I haven’t looked up an actual power band chart but I have found the gear ratios. Right now I have it figured for using 2nd gear with an 18T to 20T final drive sprocket. The engine redlines at 13,500 rpm which should give me 3,162 rpms at the prop shaft and at 12,000 rpms it should be 2,811 rpms at the prop shaft. I can tweak as needed with other sprocket and bike transmission ratios. I am open to all insight.

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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sat Mar 17, 2018 9:34 pm

I got the original cbr shift lever mounted to the frame so gear changing is available if needed. It should just stay in 2nd gear most of the time and Mayans neutral periodically. I will try and bypass the neutral position sensor and use the clutch if necessary when starting to prevent putting too much drag on the starter. Plus it might be fun having the clutch. I also welded up a fuel tank. If my math is right it should be about 4.5 gallons. Its larger than the Honda Cbr tank so hopefully it will run a while on that. I picked up a new batter for the boat. After I leak test the tank I am going to try and thin down some of the excess wiring on the harness and start the engine. It’s been a while since I heard it run last and I didn’t run it long.

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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby swamper2 » Mon Mar 19, 2018 8:56 am

See how it runs but I would be thinking about a belt for the power to the jack shaft. It would be smoother and less maintenance/reliable
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sat Mar 31, 2018 10:35 am

Going with a belt may definitely be in the future if it runs well then I could definitely see investing in a belt and a couple pulleys. Radiator is plumbed, fuel tank is finished, I cranked the engine and she is runnin great! I had some tubing rolled to get started on the cage.
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Mon May 07, 2018 6:58 pm

I built the cage using 3/4” square tubing rolled to about 76”. I wove 3/32 welding rod for the mesh in a 3”x 3” pattern and I think it turned out pretty descent. I tried tack welding some of laps together and it caused a ton of expansion and distortion in the rod so I decided to leave it alone.

I need to add some tabs and angle to mount the cage to the hull and engine stand but all of that alignment stuff is on hold until I get a prop and make a prop/shaft adapter. The engine stand has not been mounted to the hull yet either.
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Mon May 07, 2018 7:07 pm

Got started on the control box and I thought I might utilized the cluster from the Honda cbr since I had it laying around. I will admit it is not my finest work. I started welding the enclosure a little hot from the start and made a mess but at least it’s down towards the bottom. The gauge cluster was cracked in a few areas including the speedometer which I obviously don’t need so I took it to the band saw and this is what I was left with. The cut outs in the aluminum for the lights are a little ugly but nothing I couldn’t fix with caulk. It still needs to have some switches added, some final wiring and be drilled for a grommet.
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Mon May 07, 2018 7:15 pm

I thought a while on how to tension the chain and I came up with simple and strong. I think I got that in the design. It’s built pretty heavy and uses a 5/8” bolt to hold the idler sprocket and there is ample room for adjustment.
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Rick McC. » Fri May 18, 2018 9:23 pm

That’s a lot of DIY work!

Looking forward to the next installment... :thumbleft:
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Fri Jun 22, 2018 7:44 pm

It is a lot of diy work. I spend a lot more time thinking about what to do next and how to do it.

I’ve been praying for a good deal on a prop and the good Lord has provided. I found a good deal on a 70” warp drive 3 blade in excellent condition. It does not have nickel leading edges so I will get that done when I tear the boat down for paint.

At least now I can start making some progress again. Next on the list is making a prop shaft adapter which will feature a little turning and milling. Then figuring out cage and engine stand mountin locations and building the seat stand.
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Rick McC. » Fri Jun 22, 2018 11:21 pm

Excellent!
"Sights are for the unenlightened."
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