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Reverse-Engineering an overbored KTM525

Anthony Gatlin, Richard Leathers, Robert Willis. Reverse-Engineering an overbored KTM525. Objective. GOAL: Create a mockup of an over-bored KTM525 so that further study and redesign can be conducted. KTM525 engine will be used on the Formula Hybrid Challenge race car in the future.

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Reverse-Engineering an overbored KTM525

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  1. Anthony Gatlin, Richard Leathers, Robert Willis Reverse-Engineering an overbored KTM525

  2. Objective • GOAL: Create a mockup of an over-bored KTM525 so that further study and redesign can be conducted. • KTM525 engine will be used on the Formula Hybrid Challenge race car in the future.

  3. The Beginning… • Started with a partially disassembled engine and no previous experience with the MicroScribe Reverse Engineering system.

  4. The MicroScribe… Modeling a cylinder head gasket with the MicroScribe

  5. The MicroScribe… The tip being used to “scan” the piece we are working on

  6. Results of our Labor… A rendered representation of the cylinder, created with a combination of FARO arm use and manual modeling

  7. The Real Parts… The bored-out KTM525 cylinder

  8. Another Part Reverse Engineered… The features of the clutch cover are normally hard to capture with conventional techniques

  9. Another Part Reverse Engineered… While this gasket is easy to model with conventional methods, the MicroScribe cut down on the effort involved.

  10. Another Part Reverse Engineered… The interface when you are working with the MicroScribe. The stylus is represented by the red cylinder in real time.

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