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P.
Red Rocket
Joined: 14 Feb 2008
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| Fladdem |
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Fladdem
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Joined: 29 Jun 2011
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 Posted: 12:41 - 09 Feb 2014  Post subject: |
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That's really cool now.
I want a two stroke nutter bike so much now, it'd be a steep learning curve for me offroad, I'm a lazy rider, and my TTR encourages it.
But even my mates DT125R gives me a grin, and that's just a tame bike.
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Current:1991 Honda MT50 (Soon to be a H100/MTX/MT5 hybrid), 1976 Honda Cub C70, 2005 Honda Varadero 125, 1993 Yamaha TTR250 Open Enduro , 2010 Road Legal Stomp YX140, 1994 Honda CRM 250 MK III, 1999 Cagiva Mito 125, 1992 Honda CB400 Super Four, Stomp T4 230, 1984 Honda H100s, 2009 Sym XS125K
Past:2003 Aprilia RS125, 1982 Kawasaki GPZ550(FREE BIKE!)
I'm having more fun than a well-oiled midget. |
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| J D |
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J D
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Joined: 08 Jul 2007
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| Posted: 13:39 - 10 Feb 2014 Post subject: |
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How do you rate the clock? Accurate? Need something for my drz.
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m0l0t0v wrote: Chris, just so you know, JD is a nutter 
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| _Iain_ |
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_Iain_
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| _Iain_ |
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_Iain_
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Posted: 10:53 - 12 Feb 2014  Post subject: |
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Recovered it.
https://i.imgur.com/GYVxiDw.jpg
Gearbox locked up after fitting a new clutch.
Got it back and the other half helped strip it all down & get the motor out. She's started showing a bit of interest in mechanics and such lately so figured MX bodyworks an ideal place to start.
https://i.imgur.com/4coZvhQ.jpg
We've got the motor on the bench at the moment, clutch cover off and the basket wobbles. This combined with lack of 5th gear and the iffy top end means I may as well just totally rebuild the bottom end, gearbox and top end & do it all propperly so I've got nothing to worry about later on.
££££ 
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Please be aware that the above post may be full of complete nonsense.
Riding: '07 KTM Duke II, Baotian BT49QT-20 Driving: '88 Volvo 340 |
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| _Iain_ |
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_Iain_
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| garth |
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garth
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| _Iain_ |
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_Iain_
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| wots |
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wots
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Joined: 30 Aug 2012
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| Posted: 20:34 - 23 Feb 2014 Post subject: |
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| _Iain_ |
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_Iain_
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| Posted: 11:36 - 03 Mar 2014 Post subject: |
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Slight update,
Went to see Pete, who's got some really awesome tools.
Basicly, he made up some things to hold the gears, then cut the worn surfaces back. I got to have a little bit of a play with a lathe too which was interesting, however have never been so scared of breaking something in my life
https://i.imgur.com/34RRdnE.jpg
Will get some photo's of after when the engine is getting rebuilt.
He also had a go at the old head - Cant hurt to have a useable spare & with a minty fresh head to work out what sort of shape it should have he was able to refurb it. I've got a photo somewhere, but cutting the dome actually involved making a tool up to do it.
https://i.imgur.com/cHMU6q0.jpg
New head on the RHS, old head on the LHS.
Which is incredible given I gave it to him looking like this;
https://i.imgur.com/mjkKTiO.jpg
And before I'd had a go at it, it looked like this;
https://i.imgur.com/FD781Hy.jpg
Proof that pretty much anything can be salvaged, and that it's always worthwhile getting a second opinion!
Really enjoyed myself, learned a lot too. I've got a few more photo's of the various stages of how he fixed the head, will upload later on.
On the subject of the machining, finally got the photo's uploaded.
First skim on the mating faces;
https://i.imgur.com/NkllYkn.jpg
Then cutting the squish band;
https://i.imgur.com/3fuSCsF.jpg
https://i.imgur.com/NS9OuQx.jpg
What seperates a bodge from a clever bit of engineering?
Pete did some measuring, and made this up. It looks very suspect, but is incredibly well thought out!
https://i.imgur.com/4SyR2tk.jpg
And then used it to cut the dome back into my head exactly as measured on the replacement. It worked very very well - proof that you don't always need to just go and buy something to do a decent job!
https://i.imgur.com/Dr6R1qh.jpg
By pulling the lever end of the tool he'd made whilst the tip (modified lathe bit) was in contact with the head it cut the perfect dome you see on the head.
The technical explanation of what happened & the machinery used;
| Pete. wrote: | It is indeed, made in 1942 for the war effort. A ton and a half of solid high-precision machine.
I let Iain loose on my other lathe making some fixtures to hold the two gears that needed the dogs grinding. In the meantime I made the radius tool.
First I had to measure the radius of the combustion chamber. To do that I simply selected an appropriate-sizes new jubilee clip and adjusted it so it was a nice fit in the dome, then measured the diameter - 59.8mm so we called it 60. Then I got a bit of flat bar and drilled 8mm hole in it about 30mm from the end, and then drilled and tapped a 4mm hole to hold a triangle carbide insert so the tip was 30mm from the centre of the 8mm hole, to give a 30mm radius at the tip. I could have adjusted the radius slightly by rotating the tip but as it happens it was spot on. An 8mm shoulder bolt with a washer underneath (and some packing nuts on top coz I couldn't find one with a short enough shoulder) and fixed it to a 1-2-3 block and away we went, just taking light cuts with hand-ressure steadying the tool and wd40 for lubricant. Took about 10mins to re-cut the dome and radius going carefully.
Incidentally, the re-worked head is just 1.06mm shorter than the bought one from gasket face to clamping nut - not enough to even think about. It must have been about 0.4mm taller to start with since I took off about 1.5mm to clean everything up. |
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Riding: '07 KTM Duke II, Baotian BT49QT-20 Driving: '88 Volvo 340 |
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| _Iain_ |
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_Iain_
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| 331X2 |
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331X2
Crazy Courier
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| Tim.. |
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Tim..
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| _Iain_ |
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_Iain_
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| paddlesat16 |
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paddlesat16
Crazy Courier
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| Posted: 21:22 - 17 Mar 2014 Post subject: |
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Wow, a lot of work gone into that bike  
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I once saw a bloke shagging a donkey.... in Saudi arabia. Theory Test Passed 26/10/09 Mod 1 Passed 26/4/10, Mod 2 Passed 7/6/10 Current Bikes Suzuki GSX1400 K5, Aprillia Pegaso 650, Suzuki DR350T. |
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| _Iain_ |
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_Iain_
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Posted: 18:31 - 28 Mar 2014  Post subject: |
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Engine goes in.
https://i.imgur.com/RcaGo5u.jpg
https://i.imgur.com/bLsG0Nr.jpg
Also put a new plate on it that won't break.
https://i.imgur.com/5Ud1eiT.jpg
Well it did start up.
https://youtu.be/YkQoamrUpAw
Put far too much oil on stuff when rebuilding it so it fouled a plug first time attempt, but got going in the end & ran okay. Rode it around a bit, was lulz.
https://youtu.be/OIpYQwpKECk
However theres a slight bit of coolant weeping from the head, and it lost around 100ml in 1.5hrs run time. At around 1.7-1.8hrs it started steaming up & really leaking. Having swapped the head gasket & ran a different head I think the top of the barrel isn't too clever so am sending it off to be skimmed & linered to get it up to spec as just getting it skimmed with scratches on the barrel is false economy.
The piston only has 1.8hrs of light use on it so there's no sense replacing that, I'll just re-ring it unless there's damage due to the barrel being worn.
The good news is the rebuilt gearbox selects all the gears perfectly there's no issues there.
Pete is a wizard.
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Riding: '07 KTM Duke II, Baotian BT49QT-20 Driving: '88 Volvo 340 |
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| Doovy |
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Doovy
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P.
Red Rocket
Joined: 14 Feb 2008
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| Posted: 09:32 - 10 Apr 2014 Post subject: |
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Indeed, I'll be visiting Iain tonight in hospital... will update y'all  |
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| garth |
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garth
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| Posted: 10:49 - 10 Apr 2014 Post subject: |
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| Paddy. wrote: |
Indeed, I'll be visiting Iain tonight in hospital... will update y'all |
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Red Rocket
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garth
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G
The Voice of Reason
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Red Rocket
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| Posted: 11:47 - 10 Apr 2014 Post subject: |
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Serious enough I think, smashed hand having pins and plates in later today. Gonna head over and laugh at him. Repay the favour and that  |
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| wots |
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wots
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Red Rocket
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Old Thread Alert!
The last post was made 10 years, 12 days ago. Instead of replying here, would creating a new thread be more useful? |
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