ORIGINAL: cmoulder
Started mulling over the nose ring design for the Focus.
It does not look feasible at all to make something that anchors to the firewall. As Matt suggested, some reinforcement of the cowl and then attaching the nose ring mounts to the inside of the cowl, and adding to (or beefing up) the cowl firewall attachment fastemers, is the logical way to proceed.
I understand that Syssa plans to make the nose rings, but since they aren't available yet I will make one from ply as I did with the nose ring for the YS110 in the Focus Sport. Circular hole with a cut-out for the Hall sensor... I know, make damn sure the nose ring doesn't contact the Hall sensor at any time.
Hopefully, the weight of whole modification won't exceed 2 oz.
Bob,
I like your thinking. Let me see if I can explain what Ed, Todd and me discussed and se if you can proceed down that path
The hall sensor does not have to be potted in the current housing. The actuall hall sensor is tiny so building a ring that surrounds the sensor and secures to the crankcase is the first step. This piece may be made in two pieces and the assembly can be secured onto the case. The outside OD can be polished and the nose ring can be slipped over this assembly. In other words, the first ring is a rather thin protector, a spacer if you will, of the hall sensor with an outsiide diameter that is intact to accept the nose ring
Nothing wrong with a plywood ring to house the current sensor pot. That's how I was going to make mine and may still do it if Todd's protector/spacer ring doesn't become available in time. The main difficulty is in machining the ply protector ring true and then adding a pair of bolts across the plane of the ring to secure it in place. I'm thinking 1/4" thick which will accept 4-40 bolts/blind nuts.
The actual nose ring would be made from rubber sheet. I have some nice 3/16" stock that has worked great in past projects.
The weight of the whole contraption should be less than 1 ounce
Matt