Motorsport specialist brings manufacturing in-house

Dunbar Race Engineering regularly makes parts for Yamaha two-stroke racing motorcycles, which were popular in the 1970s and 1980s

Located in Dalbeattie, Dunbar Race Engineering was established in 2018 by Duncan Dunbar to design and supply prototype motorcycle parts and small batches of components for the motorsport market. The company also reverse engineers and remanufactures parts that are no longer available, especially for historic and emerging classic racing motorbikes. Today, the firm provides engineering and manufacturing services to other sectors as well, including parts for internal combustion engines targeting the hydrogen market.

At the outset, production of parts was outsourced to sub-contractors. However, Duncan realised that to increase flexibility, reduce lead times and ensure consistent quality, it would be necessary to progress from a home workshop and move to manufacturing in-house. So in the spring of 2022, he moved the company into an industrial unit and purchased a Hurco VM10i three-axis vertical machining centre (VMC) with a fourth-axis rotary table.

Before deciding on the Hurco VMC, Duncan made sure he researched the market thoroughly. Hurco was recommended by a former colleague and a visit to the supplier’s High Wycombe facility followed. Being new to machining, he was looking for more than a machine tool provider, but a company with which Dunbar Race Engineering could partner. Especially important was assistance through the early stages of first-time CNC programming, as well as a clear path to more advanced machining capability in the future. Duncan confirmed that Hurco’s training was very good and its applications engineers have been very supportive with programming and advising how different jobs should be set up.

Cracking machine
Describing his experience of dealing with Hurco, Duncan said: “They are nice people to work with and the VM10i is a cracking machine. It has a large working area for its footprint and fitted neatly into the space we had available.”

Pictured right: an aluminium rear brake calliper bracket machined by Dunbar Race Engineering

To make excellent quality parts to fine tolerances, sometimes as tight as ±10 microns, the manufacturer takes full advantage of both the Hurco machine’s build quality and the conversational programming power of the WinMax control, which Duncan says is easy and intuitive to use. Most work, including complex jobs requiring 3+1-axis machining, is programmed directly at the control. Toolpath simulation and verification graphics help to avoid any potential input mistakes. Duncan confirmed: “What you see on the screen is what you get on the part.”

His career as a mechanical design engineer started with superbikes and MotoGP and continued with Mercedes AMG High Performance Powertrains. He retains an enthusiasm for all things motorsport but is keen to emphasise that Dunbar Race Engineering is not solely a racing company. He believes that the discipline, drive and innovation that forges a career in motorsport can be applied to deliver design projects and manufacture products for a wide range of mechanical systems.

Additional expertise is offered, such as inspection and quality management system services using a Mitutoyo coordinate measuring machine. Customers also benefit from the experience of time-served manufacturing engineers that can be called upon at any stage of a project to analyse, redesign and improve a process ahead of final sign-off.