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Post by yamark on Jun 23, 2024 18:53:42 GMT 1
Evening lads, hope everyone is well  . I've been very busy with work and life, but behind the scenes doing a bit of bike building. A while back I bought an RD400D with a view to turn it into a 600 triple. It was in a very sorry state. When I saw it, I thought it might have been at the bottom of the canal  . UK reg, and cheap, but rusty and hacked to pieces. It has unknown Kawasaki wheels, brakes, LC swingarm and has had the rear section of frame bodged.  SDC12308I looked in the pile of bits that came with it and this is the lower crankcase  SDC12309 And the upper  SDC12310 The selector drum came out with a bit of persuasion  SDC12311 But the tacho drive was seized solid, so I decided to cut and drill it out  SDC12313  SDC12312 I've parts collected the front and rear suspension, wheels, carbs, tank, oil tank etc, plus lots of essentials for the build. I remember Dusty saying how hard it is to get A/C parts, he's not wrong. Dusty and Alex have been super kind with supplying parts- this project wouldn't have gone ahead without their help. Alex supplied a frame that has some bracket on and it's in great nick The plan is to spread the frame 20mm, curve the front frame tubes and get the engine mounts fabricated and crankcase cut/milled and welded This is going to be a slow burner, so I'll try to post as often as I can. Cheers, Mark  |
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Post by andy748 on Jun 23, 2024 19:08:54 GMT 1
Welcome back Mark, looking forward to this one, it'll be a cracker as usual. Andy.
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Post by lcmarky on Jun 23, 2024 19:45:10 GMT 1
Blimey that really is a project!
Please be careful to check the chassis is strong and not too corroded to be safe.
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Post by dusty350 on Jun 23, 2024 20:02:02 GMT 1
'Bout bloomin time !! Less Golf and more bike building  Good to see you back mate |
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Post by bezzer on Jun 23, 2024 20:54:48 GMT 1
I’ve been dreading weeks of the Olympics looming, this is the saviour 😁. Great to see another build taking shape Mark, looking forward to this 😊.
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Post by donkeychomp on Jun 23, 2024 21:32:19 GMT 1
Golf? GOLF?? Fecks sake.
Alex
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Post by archloafer on Jun 23, 2024 22:00:08 GMT 1
Wow! A noble endeavour, bringing that back to life. Will follow this with interest...
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Post by Tobyjugs on Jun 23, 2024 22:29:01 GMT 1
Hi Mark welcome back to the forum.
One question must have missed something but what happened to the 4 cylinder LC?
Have you sold it?
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Post by sidney81 on Jun 24, 2024 7:17:18 GMT 1
Nice to see you back mark 👍
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Post by yamark on Jun 24, 2024 15:54:35 GMT 1
Welcome back Mark, looking forward to this one, it'll be a cracker as usual. Andy. Thanks Andy, I hope so. I only know of one other 3 cylinder aircooled- Harry Hawkins C model |
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Post by yamark on Jun 24, 2024 15:58:53 GMT 1
Blimey that really is a project! Please be careful to check the chassis is strong and not too corroded to be safe. lcmarky, the frame is very poor, especially the horizontal tubes. The headstock looks good though  Nearly all of this frame will be scrapped |
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Post by yamark on Jun 24, 2024 16:01:15 GMT 1
'Bout bloomin time !! Less Golf and more bike building Good to see you back mate Thanks Dusty Don't forget I have to find time for Dominos, plane spotting and rearranging my sock draw daily |
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Post by yamark on Jun 24, 2024 16:02:24 GMT 1
I’ve been dreading weeks of the Olympics looming, this is the saviour 😁. Great to see another build taking shape Mark, looking forward to this 😊. Hi Iain, I think it's going to be an Olympic build |
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Post by yamark on Jun 24, 2024 16:08:35 GMT 1
Alex- see my reply to Dusty Thanks Archloafer, it will live again Cheers Chris (sidney81), nice to be back, although I always look at the build thread regularly. |
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Post by yamark on Jun 24, 2024 16:19:21 GMT 1
Hi Mark welcome back to the forum. One question must have missed something but what happened to the 4 cylinder LC? Have you sold it? Hi Tobyjugs, I still have the 4 cylinder LC. I believe I'm the only person to own a 2,3 and 4 cylinder LC. The triple took lots of time to develop and at the moment, I don't have time to do the same on the 4 cylinder. I think parts for the A/C's are getting scarce, also beginning to dry up for LC'c and the YPVS, so I'm concentrating on parts collecting and bike building- development will come later. Like Dusty, I like the build challenge, not riding bikes so much. I occasionally get out on my 2007 R1, it's done 2,700 miles from new! Cheers, Mark |
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Post by abar121 on Jun 24, 2024 19:44:45 GMT 1
Great to see another project Mark.
Following with plenty of interest!
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Post by donkeychomp on Jun 24, 2024 21:59:40 GMT 1
Good to see this moving forward mate. Let me know if you need any other bits.
Alex
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Post by mouse on Jun 28, 2024 9:23:39 GMT 1
Going to be another amazing project, cannot wait to see more of this!
Mouse
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Post by lcmarky on Jun 28, 2024 10:33:02 GMT 1
Blimey that really is a project! Please be careful to check the chassis is strong and not too corroded to be safe. lcmarky, the frame is very poor, especially the horizontal tubes. The headstock looks good though Nearly all of this frame will be scrapped Good to hear.. Not that it's poor, but that you'll sort it. I have another question about adding cylinders that has me thinking though: How do you join the cranks and manage the ignition timing? This really is something I'd like to do too at some point. |
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Post by jon on Jun 30, 2024 12:25:25 GMT 1
Yamark, welder at the ready if your interested again?
Jon
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Post by yamark on Jun 30, 2024 20:13:05 GMT 1
Thanks abar121, Alex and Mouse- any encouragement helps |
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Post by yamark on Jun 30, 2024 20:28:49 GMT 1
lcmarky, the frame is very poor, especially the horizontal tubes. The headstock looks good though Nearly all of this frame will be scrapped Good to hear.. Not that it's poor, but that you'll sort it. I have another question about adding cylinders that has me thinking though: How do you join the cranks and manage the ignition timing? This really is something I'd like to do too at some point. Hi lcmarky, the air cooled cranks are a splined fit to join the 2 inner flywheels, the 250's, 350's and 400's have 12 splines. So if you think of a clock face, you can connect a triple at 12,4 and 8 o'clock(120 degree crank), a 4 cylinder at 12,3,6,and 9 o'clock(90 degree crank). You simply need 2 cranks for a triple and 3 cranks to make a 4 cylinder. Ignition is sorted by moving one set of points to 120 degrees and adding another set of points at 240 degrees- sorted . You're welcome to PM me on anything to build a multi A/C or LC. Cheers, Mark |
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Post by yamark on Jun 30, 2024 20:32:42 GMT 1
Yamark, welder at the ready if your interested again? Jon Jon, that's such a kind offer considering how beautifully you spread and braced my 700LC. I think I'm sorted, but nice to know you're on standby if I make a big muller Thanks Jon, hope you're good |
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Post by yamark on Jun 30, 2024 21:43:16 GMT 1
Engine next, 2 sets of cases about to be transformed.(I took pictures of a set of LC cases, but same principal for the AC) I first mill the main cases where they are to be joined (Images are of an LC engine)  SDC12314 I then cut the rear section after marking out the material to be removed (LC shown)  SDC12315 The main set of cases are trimmed to receive the out rigger section (LC shown)  SDC12317 The second set of cases are then cut (LC shown)  SDC12330 The left (new number 1 cylinder) crankcase milled (LC shown)  SDC12316 And finally the 400 A/C main cases milled (this is the right side of the join between no. 1 and center cylinder)  SDC12329 Sorry it's poorly pictured, I did 2 sets of cases at the same time and didn't take many A/C pictures Cheers, Mark |
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Post by lcmarky on Jul 1, 2024 8:36:02 GMT 1
Good to hear.. Not that it's poor, but that you'll sort it. I have another question about adding cylinders that has me thinking though: How do you join the cranks and manage the ignition timing? This really is something I'd like to do too at some point. Hi lcmarky, the air cooled cranks are a splined fit to join the 2 inner flywheels, the 250's, 350's and 400's have 12 splines. So if you think of a clock face, you can connect a triple at 12,4 and 8 o'clock(120 degree crank), a 4 cylinder at 12,3,6,and 9 o'clock(90 degree crank). You simply need 2 cranks for a triple and 3 cranks to make a 4 cylinder. Ignition is sorted by moving one set of points to 120 degrees and adding another set of points at 240 degrees- sorted . You're welcome to PM me on anything to build a multi A/C or LC. Cheers, Mark I'm not familiar with the AC motors & will re-read your 'How To' post again a few times, but I guess you have the top barrel mount face as a Datum? Distance between centres for the crank web/piston centreline I presume also that you keep to standard pitch? |
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Post by cbm on Jul 1, 2024 9:19:33 GMT 1
Oh, so you're still talking to us all then Glad you've decide to share your latest build, not only are they good to follow they encourage and inspire others too 👍 |
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Post by yamark on Jul 1, 2024 20:23:29 GMT 1
Hi lcmarky, the air cooled cranks are a splined fit to join the 2 inner flywheels, the 250's, 350's and 400's have 12 splines. So if you think of a clock face, you can connect a triple at 12,4 and 8 o'clock(120 degree crank), a 4 cylinder at 12,3,6,and 9 o'clock(90 degree crank). You simply need 2 cranks for a triple and 3 cranks to make a 4 cylinder. Ignition is sorted by moving one set of points to 120 degrees and adding another set of points at 240 degrees- sorted . You're welcome to PM me on anything to build a multi A/C or LC. Cheers, Mark I'm not familiar with the AC motors & will re-read your 'How To' post again a few times, but I guess you have the top barrel mount face as a Datum? Distance between centres for the crank web/piston centreline I presume also that you keep to standard pitch? Great questions , the first thing is to mill the cases to the correct width where the 2 main bearings and labyrinth seal sit (it's 47mm on the LC, can't remember on the 400). A dummy crankshaft and gearbox shaft are installed, cases bolted together and welded. If the "new" left crankcase face is not in line(where the barrel sits, I use a different thickness base gasket. The top of the cylinders must line up. The crankcase join is midway on the labyrinth seal. If you look at my RD550lc triple thread, the detail is there' cheers, Mark |
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Post by lcmarky on Jul 1, 2024 20:53:59 GMT 1
I'm not familiar with the AC motors & will re-read your 'How To' post again a few times, but I guess you have the top barrel mount face as a Datum? Distance between centres for the crank web/piston centreline I presume also that you keep to standard pitch? If you look at my RD550lc triple thread, the detail is there' cheers, Mark I will do just that. Thx. |
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Post by urbantangleweed on Jul 1, 2024 23:17:25 GMT 1
This will be fabulous I have no doubt.
Looking forward to see it come along.
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Post by JonW on Jul 2, 2024 8:58:37 GMT 1
Another great project! Lovely!
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. 
. UK reg, and cheap, but rusty and hacked to pieces.
