Topic: Building an endurance engine

[livefast_dieold]

Nice crank work Livefast.....you could take the lightening a bit further and still get benefit if you wanted to?

well, I told the machinist to remove as much material as he could but not to touch the balls that block oil passages or the rods' wall (I hope you understand  ). The crank has been lightened of 1 kg, now it's 8.7 kg.

[voxonda]

My crank is almost the same as yours, just a bit lighter 8.5 kgs. Think it is the way to go on a endurance engine, you want more 'driveability' than required on a dragbike or a allout racer.


Rob

[bwaller]

Wow too bad about those rocker pads after all the work lightening. Was it shot or glass bead?

I don't think they can be used that way, not sure how to save them either, others surely will.  If the surface is badly damaged enough they can be hardwelded.

[lordmoonpie]

Nice crank work Livefast.....you could take the lightening a bit further and still get benefit if you wanted to?

Very very nice LMP, did you get that work done in the UK?

Sure did Rod - Basset Down Engineering, true wizards of everything crankshafty!

[livefast_dieold]

Hey guys!

How are you doing? I'm quite under pressure cause I've to finish the bike asap, plus I'm getting graduate in two weeks and I have still a lot to work to do on my final essay (God knows how stressful can be use finite elements codes such as Ansys).

The engine is almost done:



Yesterday I've checked valve clearance and compression ratio, good news the pistons from the kawa kz650 are a direct bolt in (2 mm of gap between valve and piston using a cam with .360 valve lift), with a final compression ratio of 11.5:1!
Now the frame: I had previously cut off everything unnecessary like central and later stands mounts and so on. Since I had bought a wonderful MIG welder (graduation presents from dad  ) what do you suggest to stiffener the frame?

At the end I'm using stock carbs because I used the budget for a very rare find: a pair of Ceriani front forks dedicated to honda cb 750 dia 38 mm! And it comes with an Hilber rear fork 
Too bad the front forks need the early type brake caliper, anyone has a pair to sell in europe (with mountings)? I also need a brake disk.

Fun fact: while assembly the engine I thought to get rid of the kick starter and its cogwheel...luckily I realized that I need that for oil pumping 

[livefast_dieold]

Also, tyres issue: what size and brand do you suggest? Consider that my wheels' size are original.

[MRieck]

 What did you do about those rocker arm pads? Hardweld?

[livefast_dieold]

What did you do about those rocker arm pads? Hardweld?

No, it wasn't necessary. I polished them and find out that the superficial treatment (chrome?) was only rughened but it's still present.

[MRieck]

 As a side note....I have routinely removed the oil galley balls in the crank counterweights. It allows you to get in there with a galley brush and cleaning fluid to get ever bit of crap out of there. You just tap for a 1/4" X 20 Allen set screw and Loctite  to close it up

[Doctor_D]

As a side note....I have routinely removed the oil galley balls in the crank counterweights. It allows you to get in there with a galley brush and cleaning fluid to get ever bit of crap out of there. You just tap for a 1/4" X 20 Allen set screw and Loctite  to close it up

Any special trick to removing the galley balls?

[Sam Green Racing]

big hammer

Sam.

[lordmoonpie]

Barnsley screwdriver! 

[Sam Green Racing]

Yeh, that'll do.

[MRieck]

As a side note....I have routinely removed the oil galley balls in the crank counterweights. It allows you to get in there with a galley brush and cleaning fluid to get ever bit of crap out of there. You just tap for a 1/4" X 20 Allen set screw and Loctite  to close it up

Any special trick to removing the galley balls?

 You grind down the ball until it is flush with the counterweight. You than strike the edge of the ball with a punch/hammer and the ball will "roll over" and out of the galley. So Sam is right...you need a hammer. LMP.... I don't know what a Barnsley screwdriver is.

[Doctor_D]

Barnsley screwdriver! 

Barnsley screwdriver? Must be some kind of pommie joke.

You grind down the ball until it is flush with the counterweight. You than strike the edge of the ball with a punch/hammer and the ball will "roll over" and out of the galley. So Sam is right...you need a hammer.

Sounds easy enough.  Thanks.

[Doctor_D]

Found a definition for Barnsley screwdriver: Lump hammer

 

[MCRider]

Found a definition for Barnsley screwdriver: Lump hammer

 

Yeah, so what's a lump hammer?

http://www.classicmechanics.com/editorial.htm

More obscure references. Barnsley SCrewdriver down near the bottom.

[livefast_dieold]

Hi everyone! Sorry for the long absence but I finally manage to graduate (cum laude  ) and to finish the engine.
Pics:

The head with hemi chambers (final volume 23.5 cc)


The kawa kz 650 pistons in position:


Exhaust port with a "step" above valve seat to avoid the return of combusted gases in the cylinder:


Intake


More pics soon, bike starts to have its proper shape and not a bunch of pieces around the workplace...

[MRieck]

Hi everyone! Sorry for the long absence but I finally manage to graduate (cum laude  ) and to finish the engine.
Pics:

The head with hemi chambers (final volume 23.5 cc)


The kawa kz 650 pistons in position:


Exhaust port with a "step" above valve seat to avoid the return of combusted gases in the cylinder:


Intake


More pics soon, bike starts to have its proper shape and not a bunch of pieces around the workplace...

Where did you get that head gasket?

[kos]

Hi everyone! Sorry for the long absence but I finally manage to graduate (cum laude  ) and to finish the engine.
Pics:

The head with hemi chambers (final volume 23.5 cc)


The kawa kz 650 pistons in position:


Exhaust port with a "step" above valve seat to avoid the return of combusted gases in the cylinder:


Intake


More pics soon, bike starts to have its proper shape and not a bunch of pieces around the workplace...

Where did you get that head gasket?

Is that not a Cometic...Mike?

KOS

[voxonda]

Hi everyone! Sorry for the long absence but I finally manage to graduate (cum laude  ) and to finish the engine.
Pics:
...
More pics soon, bike starts to have its proper shape and not a bunch of pieces around the workplace...

Hey Riccardo,

Congratulations on your graduation!!! One to be proud of.

Cheers, Rob

[livefast_dieold]

Hi everyone! Sorry for the long absence but I finally manage to graduate (cum laude  ) and to finish the engine.
Pics:
...
More pics soon, bike starts to have its proper shape and not a bunch of pieces around the workplace...

Hey Riccardo,

Congratulations on your graduation!!! One to be proud of.

Cheers, Rob

thank you!




The gasket is from cometic.

[MRieck]

The reason I ask is the Cometic has the small oil return holes...not the larger late model ones. I have modified them in the past. The material looked different in the pic too...almost like the old graphite gaskets.

[livefast_dieold]

The reason I ask is the Cometic has the small oil return holes...not the larger late model ones. I have modified them in the past. The material looked different in the pic too...almost like the old graphite gaskets.

my fault, it's not from cometic, it's from vesrah.



A quick question, the original brake disk are made of steel or grey iron? Because I have to buy brake pads and wondering if I can buy syntherized pads.

[livefast_dieold]

Finally it's starting to look like a bike... a lot to work still to do, and time is running out (first race on the 10 of April)



Anyone here knows if the brake disk are from steel or from cast iron?