Building crank boxes

[Suzsmokeyallan]

I put this together for the T500 crank which will go to Bill Bune for balancing and new seals and o-rings. Its also good for storing spare cranks too so its got a double purpose. The crank is positioned so the rods oppose each other through the wheels and are at their shortest length, this cuts down on width for the box and keeps them secure in the foam.
I still need to fit on the hinges and latches to complete it and a section of the foam still needs to be cut in a slotted section for the seals and o-rings to fit into for the journey to Bill.
The top inner panel is a Styrofoam piece that fills the void above the foam section which is level with the crank wheels, so it cannot move once the cover is fitted.
Somehow the photo does not seem to convey how deep the mold really is for some reason, it must be the angle of the picture.
I also have built one for Buffalo cranks but I need to bag that crank and spray in the foam to create the mold form for that box.
If anyone wants the dimensions I can send those along for each box, they were built to a premium on space saving since the first part of their journey is going to be in a suitcase.

[speedblock]

I have a GT750 crank that will also soon be on the way to Bill Bune's. What are you using for foam - regular spray foam insulation? If so that's a great idea.

[Suzsmokeyallan]

It was "quik foam" in a spray can, a one time use product. For this box I used two cans and then once it hardened I cut the top down to a level with a sharp knife.
I placed the crank in two plastic bags just in case one leaks, and positioned it in the box with some spacer blocks under it to have it spaced off the lower side.

[rbond]

That is a neat box. Is the sprayed foam removeable? If so, you make a new mold for different singles and small twins to ship in the same box too.

[Suzsmokeyallan]

If you put a plastic bag into the box first and secured it with tape to stay in the corners as well as another bag around the crank you could in fact lift out that foam insert after its formed for that specific crank and make a few inserts for other model cranks.
I guess I could get it out by unscrewing the box fittings and carefully separating the foam from it but theres no need for me to do so.

[jkevinlilly]

Excellent idea Allen.

[Suzsmokeyallan]

Just a small update, the box is now ready for its first crank shipment with hinges and latches added.

[Suzukidave]

Allan , is there another fitted piece of foam to cover the crank... i dont see one ?

[johnakay]

Allan can you make one of these?
I might need one some day if I decide to buy anothe two stroke

[Suzukidave]

A bit of team work .. Allan can make the box and you could bend up the handles John

[johnakay]

A bit of team work .. Allan can make the box and you could bend up the handles John

OOH Inever thought of that! good thinking Batman

[Suzsmokeyallan]

Dave the top of the crank wheels are flush with the foam so some Styrofoam laid on top keeps it all secure. I had though of making a piece but then the Styrofoam worked just as good.
John you plan on using that box sooner than later, if so, I may have to get a move on just for your request.

[rbond]

And John needs to make the handles, ship them to Barbados for test fitting. Maybe John should go to Barbados too for 'test' fitting IN the new box. Just a thought, a working vacation?

[johnakay]

And John needs to make the handles, ship them to Barbados for test fitting. Maybe John should go to Barbados too for 'test' fitting IN the new box. Just a thought, a working vacation?

that's a good excuse for a lone trip (if she doesn't bump me off before I get in the taxi)

[Wingspan]

Nice work. I'm now even more embarrassed of the cardboard and bubblewrap mess I shipped mine in...