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Post by Yogi on May 2, 2016 19:25:14 GMT 1
Wow it's coming along in leaps and bounds now mate I'm getting excited and it's not even mine Keep up the momentum mate it's gonna be a special bike for sure Good luck Matt
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Post by yamark on May 2, 2016 19:25:47 GMT 1
marc try ellis moore for your shaft theydo a lot of these type of things i will double check the name with my mate as he is doing a v4 rgv 500 so 2 rgv engines and he had them made special Gary, your a legend mate. The gearbox shaft is the last stumbling block on the engine.
I have found the hardest part of the build is being constantly let down by people. 3 welders (for the frame) have let me down, I was booked in for one of them, now he won't answer his phone. 2 machine shops (gearbox shaft) never got back to me, another promised a price 3 weeks ago- I've chased 4 times. Got a ridiculous ballpark price from Nova Racing. E-mailed Ignitec 3 times - no reply; the list goes on BDK can make an ignition system, but need the engine for up to 6 weeks and the alternator part is a bit sketchy.
So Gary, I admire your persistence in building your stunning RS500, and cheers for help.
Kind regards Mark
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Post by yamark on May 2, 2016 19:28:48 GMT 1
Wow it's coming along in leaps and bounds now mate I'm getting excited and it's not even mine Keep up the momentum mate it's gonna be a special bike for sure Good luck Matt Cheers Matt - still wish I had your speed
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Post by Topman350 on May 2, 2016 20:04:42 GMT 1
Awesome work fella well done gonna be a flyer and great sounds with it ;-)
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Post by Yogi on May 2, 2016 20:07:42 GMT 1
Wow it's coming along in leaps and bounds now mate I'm getting excited and it's not even mine Keep up the momentum mate it's gonna be a special bike for sure Good luck Matt Cheers Matt - still wish I had your speed Speeds easy mate if your not reinventing the wheel
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Post by Eyrey1 on May 2, 2016 21:01:54 GMT 1
mark he got back to me this morning and it is ellis moore try them you will be more than happy for ignition contact borut at zeeltronic they will help you and probably already do a ignition that you could use !
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Post by yamark on May 5, 2016 20:43:33 GMT 1
Gary, cheers for the info- Ellis Moore very helpful, and half the price of Nova Racing. Another price came in, so I now have a choice for the gearbox shaft. I'll give Zeel a call when I get some time.
Rear engine mounts pressed out and cleaned up
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In place
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Left cover cut and shaped
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Some views of the engine, welds have still got to be dressed and the cases vapour blasted, but you get the idea.
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SDC10735
SDC10734
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Post by jon on May 8, 2016 8:04:12 GMT 1
Mark, I don't know why your welder has stopped just short of the edge of the case near the rear left mount. Was it to avoid the mating surfaces? If I were you I'd split the cases and get this welded to the end, and then dress up the mating surface. I know I keep banging on about stress raisers, but it must have been drummed into me as an apprentice. This is a stressed area of the cases. Out of interest will you be removing the duplicated raised tightening sequence numbers and stamping extra ones Jon
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Post by markhoopy on May 8, 2016 11:20:17 GMT 1
Out of interest will you be removing the duplicated raised tightening sequence numbers and stamping extra ones With all the effort that's gone in so far surely the head should be used as a template for a new casting with raised numbers rather than stamped ones.
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Post by yamark on May 8, 2016 14:48:53 GMT 1
Out of interest will you be removing the duplicated raised tightening sequence numbers and stamping extra ones With all the effort that's gone in so far surely the head should be used as a template for a new casting with raised numbers rather than stamped ones. LOL My tightening sequence is going to be confusing for the cases and head.
Jon, cheers for the info - I don't know so I'll ask about the rear weld. What is surprising is how individual the line boring from Yamaha makes the cases. Once aligned with the steel bar you can see a difference in the boring position to the crankcase. I assume Yamaha bored the crankshaft and both gearbox shafts at the same time, with slight variations to "where" in the crankcases the machining was done.
Anybody know?
Cheers Jon and Mark for your interest
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Post by markhoopy on May 8, 2016 15:11:53 GMT 1
Yes Mark the crank and both gearbox shaft holes would have been bored at the same time, and there would be more than a single machine doing the cases too hence the slight discrepancies.
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Post by plumma on May 10, 2016 3:33:39 GMT 1
I think it's a great project, but one thing that catches my eye is the changes in coolant design flow and being able to achieve consists flow throughout engine, for instance blocking of the left hand thermostat housing could cause issues maybe?? But love it, keep up the good work.
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Post by mercwagonman on May 10, 2016 15:39:35 GMT 1
Love it!!......looking forward to the finished article , very envious of your talents on the mill!
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Post by paulsx on May 10, 2016 15:48:25 GMT 1
Nova do make great stuff but boy they know how to charge for it big time
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Post by yamark on May 10, 2016 18:46:12 GMT 1
Hi Plumma, I'm as certain as I can be, the head coolant flow will be fine. The biggest restriction of flow is through the cylinder head to the cylinders (three small passageways for each cylinder), as Yamaha designed. Harry has built a few of these engines (mine is identical), which have run for thousands of miles. His LC triple was built 16 years ago and to my knowledge has never been apart. No cooling issues. His ignition and charging system had modifications, and I'm following his system as I know it works. I'm looking into Ignitec and Zeeltronic as well.
Both Harry and Graham (Cinder on the forum) have been fantastic with their help. I consider them both as friends.
Paulsx, you are so right with Nova, £450 - £550 for an output shaft. I've got 2 quotes in for £250 ish (thanks Gary, Eyrey1)
Thanks mercwagonman
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Post by cinder on May 14, 2016 9:49:28 GMT 1
It's looking really good now mark.so much so that I fancy building a ypvs variant myself but using aftermarket cylinders and a stroker crank.waiting to find out if the crankshaft is splined like yours before any final decisions on parts are made.but will be monitoring progress on the output shaft as that'll be vital for the power I'll be looking for
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Post by Tobyjugs on May 14, 2016 14:04:30 GMT 1
It's looking really good now mark.so much so that I fancy building a ypvs variant myself but using aftermarket cylinders and a stroker crank.waiting to find out if the crankshaft is splined like yours before any final decisions on parts are made.but will be monitoring progress on the output shaft as that'll be vital for the power I'll be looking for I have thought about that a few times but i always wonder about the last interferance fit in the crank being able transfer that power without failing?
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Post by yamark on May 14, 2016 17:07:01 GMT 1
It's looking really good now mark.so much so that I fancy building a ypvs variant myself but using aftermarket cylinders and a stroker crank.waiting to find out if the crankshaft is splined like yours before any final decisions on parts are made.but will be monitoring progress on the output shaft as that'll be vital for the power I'll be looking for Cheers Graham. One of the prices I got in for the output shaft was going to be a bit cheaper if I had 3 made. Harry said he'd want one and thought you would as well. They also told me it was a small change in the computer programme to change the length of the shaft, so I can have shafts made for the 3 of us if you can work out the dimensions you both need.
A ypvs with a stroker crank will be mind blowing. 2,3 or 4 cylinders?
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gsexr
Thrash Merchant
Posts: 352
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Post by gsexr on May 14, 2016 21:13:04 GMT 1
Luv this thread. Great to see it coming along
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Post by cinder on May 14, 2016 22:06:55 GMT 1
Would have to be a triple mark if only for the soundtrack anyway I already have a four
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Post by midlifecrisisrd on May 15, 2016 11:56:54 GMT 1
The triple ypvs is what I drool over. May get round to it one day.
6-800cc would be awesome
Steve
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Post by yamark on May 15, 2016 19:09:46 GMT 1
Cheers gsexr and Steve, with enough money you could build a really mad bonkers engine An 800cc triple maybe, but you'd have to rob a bank first.
I thought I'd post up these images of the crankcases. You can see the internal join that has JB weld applied over the main welding. The important part is to keep the crank bearing/ lab seal spacing the same, which makes life easier for the crank builder
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Next up for modification is the clutch cover. The clutch is being beefed up with a deeper basket. So the lugs that hold the plastic cover have to go.
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Then a shoulder is left for a cover to be welded
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The genny cover is then cut up to donate the Yamaha logo for the clutch cover. The rear section is used as well for the sprocket cover.
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A comparison of the two covers
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And after careful use of the trusty Dremel, made to fit the clutch cover, ready for welding.
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Post by midlifecrisisrd on May 15, 2016 20:12:21 GMT 1
Yes realise I'd need a small fortune
Especially as I'd like it in a Spondon or Harris frame
Got this month's practical sportsbikes and there is feature on Dean from Metmachex.
He is in the middle of a straight 4 lc. Outer cylinders reversed, inners the normal way. He made the cases from scratch
Steve
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Post by Tobyjugs on May 15, 2016 20:13:32 GMT 1
Youve done a nice job on that disc.
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Post by yamark on May 15, 2016 20:36:33 GMT 1
Youve done a nice job on that disc. Tobyjugs Thanks mate.
Steve, I'll look out for that as I get that mag now and then. The four cylinders are monsters. I've seen Cinders LC and it looks an awesome beast.
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Post by arrow on May 15, 2016 20:58:39 GMT 1
Truely awesome work, everywhere.
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Post by yamark on May 16, 2016 6:50:06 GMT 1
Truely awesome work, everywhere. Thanks Gary mate, that means a lot No pump for you to overhaul as I have to go premix.
Hope you get fully fit soon
Regards Mark
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Post by Slabsideian on May 16, 2016 22:44:54 GMT 1
Outstanding mate. Very very clever stuff!
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Post by Dieseldog on May 20, 2016 22:06:04 GMT 1
Keep up the good work, very enjoyable thread to follow Picture below is of a Karel Zegers 500cc triple based on the TZ 350 with a 120 degree crank, at the time (about 1984/5) it was owned by my brother - not sure where the pic was taken but was me riding it at the time. Notice the original Bell helmet supplied with the early LC's Previously the bike was owned/raced by Geoff Johnson. Link below is about Karel Zegers, at the bottom of the page is the part about the 500, think it's in Dutch but a couple of pictures of the engine layout. home.kpn.nl/twostrokes/triples.htm#De 500 cc 3 cilinder van Karel Zegers
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Post by yamark on May 21, 2016 14:50:14 GMT 1
Dieseldog, thanks for posting. Great images and history. Nice touch- the photo of you. I remember seeing a lot of those Bell helmets around. I wonder what happened to the bike?
Cheers Mark
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