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Post by yamark on May 22, 2016 19:09:58 GMT 1
First image is the strengthening bracket made for the underside of the cases. This is the hardest part to get welded as the webs get in the way. The webs are milled out to the depth of the ali plate.
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Next up, the clutch cover. Disc has been cleaned up, then aligned and welded. The weld has to be oil tight. The welding was done by one of my best mates Dean for the princely sum of a Guinness!
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Last, I've decided to go with copper head gaskets. I'll see if they seal and if I have problems I'll O ring the head. I am concerned that there isn't enough material on the centre chamber to O ring, so fingers crossed the copper head gaskets work.
Now; I contacted Stu (stuboy on the forum) and asked if he could make bespoke copper head gaskets. He altered his computer programme and made a paper template- sent it to me. I cut the template out, it was perfect.
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Stu then sent me the gaskets for a great price. I can't recommend him enough. He did everything he said he would do and more. A man of his word, great product and a nice guy. Also all on time. He's the type of person I have surrounded myself with in business. Use him chaps - he's very good.
Head gaskets and base gaskets
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Post by Dieseldog on May 22, 2016 19:29:11 GMT 1
I wonder what happened to the bike?
Cheers Mark Bike was sold to a chap down south somewhere, if I remember correctly something about using the engine in a sidecar
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Post by Yogi on May 22, 2016 19:36:01 GMT 1
Bit disappointed it's not running yet Mark Seriously though it's like Watching your favourite show You see a bit and can't wait till the next instalment Keep up the momentum mate Atb Matt
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Post by midlifecrisisrd on May 22, 2016 20:04:28 GMT 1
Coming together nicely
Can't wait to hear it.
O ringing the head should not be a problem. My ypvs uses a single inner O ring and just silicone round the outer to seal the water.
Steve
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Post by yamark on May 22, 2016 20:17:05 GMT 1
Bit disappointed it's not running yet Mark Seriously though it's like Watching your favourite show You see a bit and can't wait till the next instalment Keep up the momentum mate Atb Matt Matt mate you're a legend. You are one of the guys on this forum that inspired me with your builds. Very kind words. Next up will be the generator, ignition, flywheel mods and left engine covers (rear sprocket section is finished) 3 covers are used for the left side, plus an extra bespoke stator plate. Just more food for thought, 3 crankshafts are used to make up the 120 degree crank for the build. Frame is away for the major mods; clutch due back in 2 weeks, then I can make the longer push rod and fit the rg250 clutch mechanism.
So you favourite show will be a long running series
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Post by KevtheRev on May 22, 2016 20:19:50 GMT 1
Well tasty , keep the pot boiling there Maureen !!
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Post by yamark on May 22, 2016 20:20:43 GMT 1
Coming together nicely Can't wait to hear it. O ringing the head should not be a problem. My ypvs uses a single inner O ring and just silicone round the outer to seal the water. Steve Thanks Steve, I've no doubt I'll be calling on your vast experience and knowledge when I have problems. Expect plenty of PM's!
Cheers Mark
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Post by dusty350 on May 22, 2016 20:29:47 GMT 1
Hi Mark Those gaskets look great - nice when things work out so well It's definitely coming on now - be nice to see the engine offered up to the frame when the time comes - then you'll really feel you're getting somewhere See you soon Dusty
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Post by Topman350 on May 23, 2016 23:09:37 GMT 1
This build is just great lots of hard work gone into it what's your thoughts on which expansions to use :-)
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Post by yamark on May 24, 2016 19:25:45 GMT 1
This build is just great lots of hard work gone into it what's your thoughts on which expansions to use :-) Thanks Dusty.
Topman, I now know how much work you put into your builds. I feel this is about 5 times harder than my standard resto's. I realise I have to make my exhaust decision soon, the look is more important than performance. So, here's what I think I've decided.
2 exhausts on the right, 1 on the left. polished end cans (TZ350 style), black expansions, stacked parallel on the right. expansion chambers not too large,
I'm on the outskirt of London, so hope not to travel too far, but will if I have to.
I think my choice is between, not in any order- Gibson, TSA, martin77, lomas,
Anybody any views?
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Post by Topman350 on May 24, 2016 20:49:11 GMT 1
This build is just great lots of hard work gone into it what's your thoughts on which expansions to use :-) Thanks Dusty.
Topman, I now know how much work you put into your builds. I feel this is about 5 times harder than my standard resto's. I realise I have to make my exhaust decision soon, the look is more important than performance. So, here's what I think I've decided.
2 exhausts on the right, 1 on the left. polished end cans (TZ350 style), black expansions, stacked parallel on the right. expansion chambers not too large,
I'm on the outskirt of London, so hope not to travel too far, but will if I have to.
I think my choice is between, not in any order- Gibson, TSA, martin77, lomas,
Anybody any views?
I like the sound of that style of pipe tricky though who to use i have the JL's but do like the old school gibsons, in my thoughts i was thinking it would look more like the GT Kettle 750 as the Higgspeed style suit that bike...your stacked system will definitely look more modern :-) I'm toying with building a 500 next if i can find an engine at the right price keep up the great work fella :-)
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Post by Eyrey1 on May 24, 2016 21:49:21 GMT 1
yer getting there mark mate ! keep up the good work ive got my 500 at home again so im going to crack on with it again now
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Post by Slabsideian on May 24, 2016 23:22:21 GMT 1
Performance fabrications (Mark Dent), he's building my engine and gonna make me some pipes. I went down to see him today and had a look at some pipes he's made, proper work of art!! (including titanium yum yum) He's only in Sunbury mate so half an hour away from you. I can put you in touch with him if you like. Looking the biz and keep up the goodness Cheers ian
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Post by unrealedd on May 25, 2016 6:39:35 GMT 1
All I can say is there's some serious talent and skills on this forum well done to all involved in making this happen and I'd also like a best mate like dean. Great work keep it coming.
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Post by yamark on May 25, 2016 6:57:44 GMT 1
Topman, Gibson (with cans), or JL are the choice I slightly favour. Dusty put up a picture of 2 "old school" allspeed pipes and that idea is growing on me. Price will come into it, but I realise it aint going to be cheap! I so hope you build a 500, I'll try and talk you into that- defo
Gary, thanks mate. I've been following your 500 build. You seem to have left no stone unturned in pursuit of excellence. Beautiful bike. I can't wait to hear it run. I think when it starts, it will be better described as erupts! Keep up the great work - your so close to the finish line.
Slabesideian - hadn't thought of Mark Dent. He is close by I'll grab those details off you and we'll have that beer very soon.
Cheers for the interest lads
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Post by dusty350 on May 25, 2016 7:05:46 GMT 1
I've got Martin77 hydroformed pipes on my 385 hybrid and they are beautifully made and very good on price i believe. Mark Dent pipes look stunning - his Facebook page is worth a look to see his work. Mouse has Marks pipes on his hybrid. I had Tsa's on a previous build and again theyare lovely pipes - so well made and the performance gains are well known.And those Gubsons i posted in the pic would look great in my opinion although the gains may be less. Higgspeeds are a pipe i have never owned. They did get a rough ride for quality in a recent thread though. Dusty
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Post by Yogi on May 25, 2016 19:19:51 GMT 1
Cheers Mark but you've long since passed anything I'd be brave enough to attempt Im just a spanner monkey with a passion for Rds Top work mate I'll have to meet up with you at the ace or somewhere similar when our bikes are done Atb Matt
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Post by oldelsieboy on May 27, 2016 15:07:41 GMT 1
Hi Mark, good to finally meet you last Sunday. Have you ever considered this configuration? Not the best photo, the centre cylinder is reversed OEB
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Post by yamark on May 27, 2016 18:10:48 GMT 1
Likewise Nigel, nice chatting to you. A remarkable picture, I don't know where you dug it up from. Paint scheme is Jap I think. I like the way the single disc brake has been retained!
Even more food for thought. Thanks for posting
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Post by jon on May 27, 2016 19:54:51 GMT 1
That's spooky.
Today I swung by my local bike shop where I order genuine Yamaha bits and bobs to pick up something I ordered.
He has had a Honda 2 stroke displayed in the window for a while now, and today I asked him about it.
Not knowing much about Honda's I asked if it was a twin 500 as I could only see 2 pipes, and 500 decals on it. I was told it was a triple and the centre cylinder had been reversed and the 3rd pipe came out of the tailpiece (which I hadn't seen as it was up against the wall).
Jon
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Post by cinder on May 27, 2016 22:15:24 GMT 1
Will be picking up some gaskets off Stuart Mark.he posted a pic on his adrenalin 2-strokes facebook page and they look class. He even sent me a paper template to try .he really is a top guy . If you p.m. your e mail addy I'll forward photos of how my old skool al lspeeds turned out stacked
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Post by Eyrey1 on May 28, 2016 3:15:22 GMT 1
mark i posted 2 vids of my 500 running didnt you see them ?
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Post by yamark on May 28, 2016 6:14:56 GMT 1
Will be picking up some gaskets off Stuart Mark.he posted a pic on his adrenalin 2-strokes facebook page and they look class. He even sent me a paper template to try .he really is a top guy . If you p.m. your e mail addy I'll forward photos of how my old skool al lspeeds turned out stacked Glad your using him mate. He did the same for me, sent a template (FOC), that fitted perfectly. He made my head gaskets and 3 base gaskets (you can choose thickness) for £42! Stu also made 2 extra, mid cylinder, head gaskets and said if I want any more he'd post them out as he'll stock them for me! Saved me about 10 hours, making imperfect head gaskets- no brainer. He knows his stuff and just such a pleasure to deal with.
I'll pm my E-mail over
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Post by yamark on May 28, 2016 6:22:43 GMT 1
mark i posted 2 vids of my 500 running didnt you see them ? Yup, I saw those vids, - got my juices flowing. But you know when your actually next to the bike and can feel the vibration, hear the noise and smell the burnt oil. I have to sample that.
I'm a bit worried that when you go full throttle, your intakes are probably going to suck in anything close, including small children
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Post by yamark on May 31, 2016 19:43:44 GMT 1
Hi Mark Those gaskets look great - nice when things work out so well It's definitely coming on now - be nice to see the engine offered up to the frame when the time comes - then you'll really feel you're getting somewhere See you soon Dusty
Just for you Dusty. Engine offered up in the frame. The rear mount is about 1 or 2mm out, so will need shortening on the left and a shim on the right. The front engine mount will need to be fabricated.
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I had a nice clutch basket, and thanks to Muttsnuts matched the lash to the crank primary drive gear he supplied So ground an drilled the rivets ready for the deeper basket to be fitted. The clutch will have 9 friction plates.
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This image shows the extra depth of the FZ600 basket. There is a bit of machining, welding, riveting to make it all work so while I did the prep work, Harry will do the hard bit
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Mark
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Post by dusty350 on Jun 2, 2016 21:06:49 GMT 1
Hi Mark Engine looks good in the frame - really helps the rear mount is virtually right . I have a set of new clutch damper rubbers in a packet that came with some spares if you need them. Might have a spare front mounting plate too if you intend modding it to fit the existing frame mounts. Really coming on now mate- keep going at this rate and you'll be riding it in no time Catch up soon Dusty
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Post by yamark on Jun 4, 2016 19:59:41 GMT 1
Hi Mark Engine looks good in the frame - really helps the rear mount is virtually right . I have a set of new clutch damper rubbers in a packet that came with some spares if you need them. Might have a spare front mounting plate too if you intend modding it to fit the existing frame mounts. Really coming on now mate- keep going at this rate and you'll be riding it in no time Catch up soon Dusty Thanks Dusty, all the clutch parts are with Harry including new damper rubbers, and I think the clutch will be back with me soon. Thanks for the offer on the front plate, but I think I need to make one from scratch, I still can't visualise the front right mount until the new frame tubes are in place. Your dead right about the rear mount, it nearly aligned up without any modding, so a good reference point.
The frame is having it's jig made and the major surgery on the frame is about three weeks away. The frame had two rusty sections, they have been repaired, pictures soon.
I now have the generator and all the ignition parts The cylinder head is away being lightly skimmed. The wheels have caused a few headaches (boring story) but I hope they are back with me soon as well. Parts from Yamaha, Suzuki and Norbo arrived this week.
Cheers Mark
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Post by yamark on Jun 7, 2016 22:08:13 GMT 1
When I bought the bike, the frame looked in fair to good condition. Except in two places toward the rear of the frame, there were 2 rusted areas as if water had been in contact with it. I forgot to take photos but they were holes about 12mm big. So the rot was cut out and repair sections cut out of an old PV frame used (thanks to Dusty for the PV frame).
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Welded in place, and profiled and rubbed down
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The 2nd repair half way through finishing
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These repairs had to be done first as below this section, the frame will be spread by 20mm.
While I was at it, I removed the bearing cups out of the headstock using a Dremel
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This image was the first mock up of front frame tubes. The frame tubes have to move as the exhausts will pass straight through the standard position. They have to go outward so I have somewhere to mount the radiator (I'll have to make new brackets)
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Lastly, work starts on the generator. The flywheel on the left is from an early CBR 600. An LC inner section will be grafted onto the Honda flywheel. The flywheel will face the opposite way to the LC, ie open side out, the reason for this will become clear later.
SDC10729 by Mark Graham, on Flickr
Drilling out the rivets - at least the swarf doesn't go everywhere!
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The LC tapered section will need a bit of machining as will the CBR flywheel. The new hybrid flywheel will clear the crankcase by about 1.5mm, again I'll explain why later.
Mark
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Post by jon on Jun 7, 2016 23:44:55 GMT 1
Mark, nice to see you are making progress with the many modifications that go into making a special.
I seem to be making slow but steady progress with my build, and it will use the original engine, so can understand how much more effort goes into something like this.
How weird to see you drill the flywheel off the boss, as I am planning this in future for a different reason. Will you get it balanced afterwards?
Jon
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Post by dusty350 on Jun 8, 2016 7:11:38 GMT 1
Hi Mark Wow, the build continues at a good pace mate The repairs to the frame look great - you would never know the repair had been done which is how you want it. At this rate yours will be finished before mine!! Great pics too. See you soon. Dusty
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