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Post by muttsnuts on Jan 22, 2014 16:14:22 GMT 1
Well its time I started a thread on this, so here goes......... As most things do, it all started in the pub over a few beers, after more beers we finally came up with this idea that it would be good to turbo a 2 stroke. After sobering up, I had a stab at my first design, see below ! Then I started to think about what I would run it in, using an LC, YPVS or RD frame seemed like too much hard work as the frame would need modding to take better tyres/wheels/suspension/brakes etc, so I looked about locally for a suitable donor bike and found this........ Its a little ZXR400H1, great little bike in its own right, not too big and a good chassis/handling etc and all of the main incredients to allow more time to work on the engine design build etc. Next was to decide on the engine to use, originally I was thinking of an LC, then a YPVS, but I've been wanting to build a engine that I've been thinking about for a while, so decided to bite the bullet This engine is a hybrid, a mix of an aircooled RD400 engine and 350LC barrels and head. The engine itself still remains 400cc, but water cooled on an air cooled bottom end, the reason for this is two fold, the 400 crank is much bigger and heavier than the LC crank and therefore will proivde good low down torque, the other reason is that its 8mm longer on the stroke than the LC so makes the engine nearly square (62mm stroke x 64mm bore) which is a good design. The challenges just to get the basic engine working are many, not least of which things like port timing, barrel/piston heights, ignition timing, how to run a water pump etc, etc Luckily I have lots of spares etc, so have built the bottom end of the engine and the crank has had TZ big ends fitted, this is the engine at the moment.... Next was to start mapping the ports etc in the 350LC and 400 Barrels, so in good old fashion style I got my paper and pencil out and traced them using the good old rubbing technique ! and then started to map the port timing.... Next the bike was stripped down to allow me to sort out the fixing plates etc required to get the engine in the frame while I was at it I straightened the frame (it was out by 1.5%) and also lengthened it a little on the head stock to match the later L1/L9 models as that is a slightly better handling bike. and of course the turbo is here...... I am currently waiting on a few bits and bobs, but progress is still happening, if only on paper for various things like the wiring diagram, the pitot tubes, the plenum chamber, fuel pump, oil tank, oil pump etc, etc, so lots ot keep me busy I'll provide some updates shortly when I;'ve made some more progress..........watch this space.......it could turn out to be one big white elephant !!
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Post by 2strokesmoke on Jan 22, 2014 17:29:16 GMT 1
Jesus I just love how some of you guys think!! Cant wait to see how this turns out, will be following this thread with interest.
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Post by Roofmonster on Jan 22, 2014 18:23:56 GMT 1
That motor fits nicely in the frame. Will it become a ZXRD440TLC ?
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Post by muttsnuts on Jan 22, 2014 19:17:50 GMT 1
I was thinking of calling it "What-the-F....." or a YamaSakiTurbo......
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Post by Roofmonster on Jan 22, 2014 19:28:29 GMT 1
I was thinking of calling it "What-the-F....." or a YamaSakiTurbo...... I like it Yamasakiturbo WTF400
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Post by steven on Jan 22, 2014 19:31:52 GMT 1
If she was mine, I,d call her "Turbinia" ....Elsie Turbinia,...LOL, sounds like an old swamp donkey I once met in the dockyard club in Rosyth !... en.wikipedia.org/wiki/Turbiniasteven.
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Post by reggieperrin on Jan 22, 2014 20:44:29 GMT 1
Cool project... Consider an electric pump for coolant, used to use one on a race bike few years back.. It worked great and you could dial in the temp you wanted almost..
Reg
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Post by muttsnuts on Jan 22, 2014 21:34:12 GMT 1
I was thinking of calling it "What-the-F....." or a YamaSakiTurbo...... I like it Yamasakiturbo WTF400 Hehe, I like that alot, I think you've just named the bike for me !! Yamasakiturbo on the tank and WTF400 on the side panels !!! and 2 fingers at the rear near the exhaust !
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Post by muttsnuts on Jan 22, 2014 21:38:48 GMT 1
Cool project... Consider an electric pump for coolant, used to use one on a race bike few years back.. It worked great and you could dial in the temp you wanted almost.. Reg Hi Reg, yes got an electric pump sorted (cost me a whole tenner !), took me a load of research though to find a 12v continuous rated pump though!, but now that I know what to use its a breeze, I intend using the ZXR radiator, fan and temp sender to control things, but the pump will run all of the time I think just because it saves me worrying about it then, but time will tell if I change my mind I've just hopefully sorted out a very trick dash as well for it, so that's great as well and I've hopefully sorted out a very nice tail unit (thanks Dusty), so I've had a good day today on it So its all coming together, done the port timings tonight for the standard 350LC and standard RD400 so I can map them now, now all I need is the offset pistons to arrive and then I should be able to do the final mapping and then work out what needs to go where to make this work, but after this evening's measurements I am feeling quietly confident this thing is going to work !
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Post by marsbar350 on Jan 22, 2014 21:47:21 GMT 1
looking forward to see this in the flesh dave.oh and the guiness
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Post by muttsnuts on Jan 22, 2014 21:55:03 GMT 1
aye, there'll be plenty of that for sure !
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Post by twostrokebrit on Jan 23, 2014 13:04:56 GMT 1
:)cool as f**k.
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Post by muttsnuts on Jan 23, 2014 15:25:38 GMT 1
had a visit from the piston an laser cutting fairy today, look what she brought me...... The laser cut plates are mint and the pistons even come in their very own little bag, how cute !! they do look the bollox I must say these pistons and at nearly £100 cheaper than buying them in the UK, a bargain too and I only had to wait 2 weeks for them from America so its full steam ahead on the dry engine build now, port timings to map etc, get the barrels rebored so that pistons fit etc and them some "blakc magic" stuff to align everything and then it will be full on getting the thing in the chassis and ready to run - that's a while off mind !
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Post by muttsnuts on Jan 23, 2014 15:29:22 GMT 1
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Post by marsbar350 on Jan 23, 2014 15:55:30 GMT 1
some nice parts dave take it you didnt get stung at customs
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Post by gammaguy21 on Jan 23, 2014 17:04:46 GMT 1
So much win in this project!!!!
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Post by twostrokebrit on Jan 23, 2014 18:39:52 GMT 1
Great thread ,will be following along , wanting to do something along these lines myself.(400LC). Why have you got 6 base spacer and 2 head spacers ?. thanks mark
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Post by muttsnuts on Jan 23, 2014 19:07:50 GMT 1
Great thread ,will be following along , wanting to do something along these lines myself.(400LC). Why have you got 6 base spacer and 2 head spacers ?. thanks mark so I can play around with the port timing without the need to commit to cutting/changing the actual ports in the barrels, plus it will allow me to work out exactly which is the bst way to go, head plate, base plate or a combo of both
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Post by twostrokebrit on Jan 23, 2014 20:03:47 GMT 1
i suspected as much but thanks for the confirmation. i wonder why Yamaha didn't make the LC a 400 from the start as they had already gone there with the RD400F, Seems like a backward step to me. i like your idea about the heavier RD crank too.
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Post by muttsnuts on Jan 23, 2014 22:27:59 GMT 1
um, hit my first set of proper technical challenges, but I have a cunning plan, watch this space.....but I suppose the issues I;ve hit are why very few people have tried to build this engine, its not bloody obvious until you do a dry build like I have tonight, some machining will be happening shortly..........
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Post by twostrokebrit on Jan 23, 2014 22:37:19 GMT 1
oh... what a tease ..gagging for some pics of the rec machineing
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Post by muttsnuts on Jan 23, 2014 22:57:22 GMT 1
yeah, will probably do that over the next few days, I'll take some piccies while I am doing it, just need to double check my figures etc, its easy to take metal off, not so bloody easy to put it back !
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Post by hooley10 on Jan 24, 2014 0:10:06 GMT 1
There is some pretty cleaver people on this site well done m8 looking forward to the rest of your build
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Post by muttsnuts on Jan 30, 2014 9:40:50 GMT 1
well I've been busy working on the engine, had to machine a good number of parts including the pistons (don't try this at home kids !) but after sorting the pistons and then the barrels, the engine now fits together and everything turns over as it should started on the port timings again, so still lots to do Also been making lots of spacers and brackets to fit the engine into the frame, so busy, busy at the moment !
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Post by marsbar350 on Jan 30, 2014 10:14:06 GMT 1
nice work dave clamping the pistons in them jaws must have been twitchy
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Post by muttsnuts on Jan 30, 2014 10:19:26 GMT 1
it was rather, given the price of them and the chances of them flying out was a tad worrying, and of course just the idea of machining them !
still, what was worse was machining the base of the barrels, given they are my best set and only on 0.5mm now after being rebored and completely standard, to say that was a little unsettling is an understatement and if this engine doesn't work then I've got a set of very unique 350LC barrels which are probably no good for anything else !!!
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Post by rob99 on Jan 31, 2014 12:20:54 GMT 1
Fantastic thread watching with waited breath for the test ride lol
Just a note on machining the pistons if you ever need to do it again make a sleeve for the outside and it will distribute the pressure from the jaws more evenly allowing for a little more pressure to be applied and lower the rusk of a flying wesco piston
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Post by twostrokebrit on Jan 31, 2014 13:05:54 GMT 1
^^^ or get some soft ali jaws and bore to suit.
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Post by rob99 on Jan 31, 2014 14:55:43 GMT 1
Id seen this ages ago and saved the pic i thought it was a great idea when i saw but i neither have the time or money to do it Good luck
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Post by muttsnuts on Jan 31, 2014 16:02:09 GMT 1
hehe, nice idea but I can see a few flaws in that design !!, it might work, but not very well for reasons I won't go into (as otherwise I'd be letting all of my secrets/hardwork go !!)
I have hit an issue with my hybrid engine which means I need to take a few steps back, and also necessitates me needing a set of barrels that I can effectively scrap, so I've put a wantded ad up for some barrels that are scrap/need relining, they must be ok structurally ok and standard porting if at all possible as I will be relining them to try out the new port layout etc
Anyway, if it was easy it would have been done already, so onwards and upwards, I expect a few knock backs/problems, so this isn't a major issue, just a hurdle that needs to be overcome, which I think I have the answer to, so I am confident the build is still possible..........
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