Kyle Riffle

Mechanical Engineer • Project Manager


PERSONAL PROJECTS



1. SRAM Code RSC Brake Guard



Surfacing, FEA, CAM and CNC



Post mount, flat mount, and International Standard - today we're lucky to only have 3 disc brake mounting conventions1. I can remember needing an expensive Hayes-to-Manitou adapter on one of my early Trek mountain bikes. But even today, we still need adapters in certain scenarios, and such is the case when changing the diameter of the rotor. Desiring to jump from 180mm to 200mm rotors, hone my SolidWorks surfacing skills, practice with FEA, protect my calipers and show off in an ever so slight way, I designed this aluminum brake guard.


After measuring the caliper and post mounts that the guard would mate to, I designed a 300-gram guard and ran Finite Element Analysis simulations using SolidWorks. The analysis relied on forces derived from real-world velocities and masses to provided realistic simulations of stress and deformation in the part. Next steps will include moving the part from SolidWorks to G-Code via the MasterCAM plugin.

[1] "What is the difference between I.S., post, and flat mount disc brake mounting standards?"



2. Automotive Solar Array



IMPROVING MANUFACTURABILITY AND FUNCTION



Normal vehicle batteries and alternators cannot withstand the rigors of repetitious high-drain applications. Requiring additional power to work from the road during a recent mountain biking tour, I utilized unused space in my Volkswagen's rear quarter panel to install power storage, conversion and distribution systems. The first step was to reversibly interface with the factory electrical system via an isolator that safely allows either system to use the other's battery and charge input. Then, a 100w panel was installed on the vehicle's roof rack and connected via a small charge controller. Finally, a DC-DC converter, a DC-AC inverter, and a timer were installed so that the necessary peripherals can be run unsupervised.



3. Santa Cruz Nomad Suspension Modification



An ongoing endeavor to increase suspension travel



Better anti-squat characteristics, plusher ride and lower weight are the advances that mountain bikers dream about. Not satisfied to wait for someone else to do it and loving to experiment, I began to research ways to modify my bike's suspension. I identified two simple solutions that had the potential to give me a plusher ride: a new rear suspension link and new front airspring. The link did exactly that, but more importantly the lengthened wheel base improved handling characteristics. I am preparing to install the fork upgrade soon, meanwhile I am searching for a coil rear shock.



4. DJ Sound System Design, Simulate & Build



Acoustical simulation, sourcing components and cabinetry



Indulging my passion for esoteric sound systems, I built this 3-way speaker set to provide exceptional low frequency output while maintaining mids and highs that could "keep up." The system utilizes tube and MOSFET amplifiers for a gentle warmth on the mids and highs, and drivers from Digital Designs and Selenium. Simulations were run using WinISD to perfect cabinet volumes and port dimensions. Shown here, a port insert allows the vented subwoofer enclosure to be re-tuned from a more traditional 36Hz down to as low as 17Hz. This affords us the rare experience of hearing and feeling frequencies normally omitted from the listening experience.



5. Mobile Sound System Installation and Competition



Overcoming a high noise floor while maintaining quality



As a professional installer I have brought to life thousands of car stereo installations, but my personal stereos receive an uncommon level of detail. Shown here, my 1990 Mazda Miata features HLCD's in a 3-way system designed for unparalleled clarity and imaging that can be heard over the noise of travelling on the highway in this tiny convertible. Drivers from Eric Stevens and JBL paired with digitally networked amplifiers from Kicker make it all possible. 1500W.