kyteler Posted September 17, 2018 Share Posted September 17, 2018 11 hours ago, Truenotch said: I was thinking about buying one of these... But my bank account disagreed. Luckily someone has posted measurements online: 38 minutes ago, TimShadboltfan27 said: amazing. did you do measurements yourself or are they online? Hmm... Quote Link to comment Share on other sites More sharing options...
TimShadboltfan27 Posted September 17, 2018 Share Posted September 17, 2018 i omitted to read the previous posts as you were chaps 1 Quote Link to comment Share on other sites More sharing options...
Popular Post Truenotch Posted September 18, 2018 Author Popular Post Share Posted September 18, 2018 Thanks KY . Here’s today’s progress: Tacked in place: Mig’d her up: I have no idea if this is going to work, but it’s been fun to muck around with. 11 Quote Link to comment Share on other sites More sharing options...
Lord Gruntfuttock Posted September 18, 2018 Share Posted September 18, 2018 Be interested to see how that pipe goes, got some software somewhere that lets you put in your engine config and it spits out the optimum tuned pipe design. Never tried it yet. 1 Quote Link to comment Share on other sites More sharing options...
Truenotch Posted September 18, 2018 Author Share Posted September 18, 2018 36 minutes ago, Lord Gruntfuttock said: Be interested to see how that pipe goes, got some software somewhere that lets you put in your engine config and it spits out the optimum tuned pipe design. Never tried it yet. Yeah, I’ve had a look at design software / spreadsheets but it gets really confusing really quickly. It seems best to have the bike already running so you can work out things like approx exhaust temperature, rpm etc. I’m pretty sure that won’t be the last chamber I build for this thing! 2 Quote Link to comment Share on other sites More sharing options...
Lord Gruntfuttock Posted September 18, 2018 Share Posted September 18, 2018 I've been tempted to build one I could slide so's I could trial different length expansion chamber in road trials. Think getting back-pulse timing right is pretty important. Black magic stuff really... 1 Quote Link to comment Share on other sites More sharing options...
UTERUS Posted September 18, 2018 Share Posted September 18, 2018 this isn't the thread i was looking for, but cool bike 1 1 Quote Link to comment Share on other sites More sharing options...
Truenotch Posted September 20, 2018 Author Share Posted September 20, 2018 Yay, parts day! Unfortunately there's a bit of work needed to make everything work. I gambled on the Polini cylinder for the Chappy being correct because of some info that I'd found on the internet, but it turns out the Polini kit has HUGE transfer ports that are far too big for my crank case. This leaves gaping holes around the edges of some of the ports... So I'm stuck trying to find a solution. You can see the difference between Polini and standard ports here: My first option is to use JB weld / some type of compound to goo up the ports on the cylinder. I'd also add goo to the mating face on the crank case to get a good sealing surface. Then I can port match the cylinder from there. Option two.... Um.... A metal gasket or something? Not sure. I also need to modify the inlet to get the reed cage to fit. It needs a couple of MM taken off to fit nicely. I'll also need to modify the chappy inlet manifold to suit. I could either add a wedge underneath to get this angle or add to the manifold with an elbow / new tube. Once I realised nothing was going to work today, I set about trying to make it go as a 50cc again. It was a pretty mad mission and I was trying to finish it in time for the oldschool meet tonight, but it wasn't to be. I got it going afterwards though! Here's my temporary headlight until I sort the wiring out: Took it for a hoon. It's going much better than the last test, but still not well. It splutters a lot, although I did double up on oils (premixing incase the oil pump didn't work) and the carb enclosure was open, so it was likely running lean, causing the splutter. I just had to ride it to make sure the next lot of effort will be worth it! And it seems like it will be... The thing is quite peppy when it decides to pull through the revs. 5 Quote Link to comment Share on other sites More sharing options...
peteretep Posted September 20, 2018 Share Posted September 20, 2018 cat was not interested in your shenanigans 1 Quote Link to comment Share on other sites More sharing options...
Truenotch Posted September 21, 2018 Author Share Posted September 21, 2018 Got it running a bit better today. The clutch slips if you don't change really gently. It goes OK though! 5 Quote Link to comment Share on other sites More sharing options...
Truenotch Posted September 22, 2018 Author Share Posted September 22, 2018 This was running pretty OK for a while until I tried to ride it to see a friend. It fired and ran once, then wouldn't start again. I reset the points and it fired up again... Once... Before deciding it didn't want to make spark anymore. I had a decent look around everything and the points and condenser seemed acceptable and I'm pretty sure the coil is OK. Then I noticed a dodgy looking of the ignition winding and gave it a poke. It broke in half and appears to have been soldered together at some stage. Hoping / am pretty sure this is where the spark ran away to. You can see little soldered bits on the end of the broken wires and the last few coils of the ignition winding are loose. I think someone bodged it up years ago to make it work. I'll take this to an electrical barry next week to see what he can do. I'm pretty sure this is the cause of my problems... But I'm not 100% sure. The wire looked dodgy before, but it wasn't broken. Only took a small bump to break the solder join though. I guess we'll find out if it was the main issue 3 Quote Link to comment Share on other sites More sharing options...
Popular Post Truenotch Posted September 23, 2018 Author Popular Post Share Posted September 23, 2018 Since the motor is on the bench I set about fitting the 45mm cylinder. First up I made a .9mm aluminium base gasket to deal with the overlap of the transfer ports. I think this will do the job. Bonded it on with CRC high temp rtv and will use the same again when fitting the cylinder. Alsi had to nip the corners off these cooling fins to get the cylinder to go all the way home. I’ve also figured out how to mount the carb - I’ll make an adapter plate to turn it 90 degrees so it pokes out the side like this: 16 Quote Link to comment Share on other sites More sharing options...
Popular Post Truenotch Posted September 24, 2018 Author Popular Post Share Posted September 24, 2018 Made this little adapter plate today. Hopefully I’ll be able to fit it up with the reed block tomorrow. Took the stator to an 87 year old man for repair. He’s going to fix it in a couple of days for $30. What a legend - he’s definitely on the right side of Barry valley. 15 Quote Link to comment Share on other sites More sharing options...
HighLUX Posted September 24, 2018 Share Posted September 24, 2018 Looking forward to this making braaaaps 1 1 Quote Link to comment Share on other sites More sharing options...
Truenotch Posted September 24, 2018 Author Share Posted September 24, 2018 37 minutes ago, HighLUX said: Looking forward to this making braaaaps Me too! It's spiralled out of control, so it better go OK. Quote Link to comment Share on other sites More sharing options...
Truenotch Posted September 25, 2018 Author Share Posted September 25, 2018 New head arrived today to suit the 45mm kit. It's a high comp head and has a huge amount more cooling area than the standard one. 9 Quote Link to comment Share on other sites More sharing options...
Truenotch Posted September 26, 2018 Author Share Posted September 26, 2018 Ignition winding rewound. Ken Cairns is great - he’s definitely getting on, but knows what’s up. This job was $30 . Missed a delivery from Yambits today... I’ll collect it tomorrow. It’s got points, clutch parts and a few other goodies to keep me busy. 9 Quote Link to comment Share on other sites More sharing options...
UTERUS Posted September 26, 2018 Share Posted September 26, 2018 He did that for $30?!? Quote Link to comment Share on other sites More sharing options...
Truenotch Posted September 26, 2018 Author Share Posted September 26, 2018 17 minutes ago, UTERUS said: He did that for $30?!? Yep. Covered everything in resin too. Champ. 4 Quote Link to comment Share on other sites More sharing options...
peteretep Posted September 26, 2018 Share Posted September 26, 2018 man thats legit you got that stuff rewound hey @Kimjon you should talk to markku about getting the wajax coils rewound. I never found anyone to do it, but could make the engine run without a battery 2 Quote Link to comment Share on other sites More sharing options...
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