A little something I have been working on

rgvlee · 13-05-2008, 10:29 AM

This has been in the pipeline for way too long. Quite a few things have prevented me from really getting stuck into this project but now it is full steam ahead.

It won't be ready for the 2 stroke party but the aim is to have the engine back together and running this weekend.

without further ado

barrels and a few other bits back from the cleaners

one of the barrels had a small chip in the coating. Not an issue, it can be cleaned up. Just need to keep an eye on it. I will end up putting this barrel on the front of the motor for easy removal later on.

some of the new parts waiting to go on. Many more to find in the parts box

cleaned up the crank case faces with some 1200 w+d. They came up really well. Checked the faces to make sure everything is straight, all good!

dressed the chip with 800 and 1200 w+d.

chamfering the pistons and cleaning the powervalve bits and pieces tonight. Top end should be back on tonight/tomorrow.

to be continued...

Orson · 13-05-2008, 10:32 AM

Satan1 · 13-05-2008, 10:33 AM

Nice lee, hope it all goes smooth

Tin Tin · 13-05-2008, 10:36 AM

cool man... good little site you have too... even if it did kill my crappy work computer lol

arwon · 13-05-2008, 10:42 AM

what heads are they DG performance?

rgvlee · 13-05-2008, 10:44 AM

cougar red heads + valves (formerly branded DCR)

straight plug, o-ringed, removable inserts, integrated water spigot, larger water jacket... can't remember what the squish is for these inserts, i'll measure once assembled.

Stratos · 13-05-2008, 12:29 PM

Very nice Lee! Are you still gonna come up with an idiots guide to squish?

rgvlee · 13-05-2008, 12:37 PM

yeah... not much to it though, couple bits of solder and a set of digital calipers... but i'll take photos anyway

thro · 13-05-2008, 03:46 PM

.... aaaand i'm spent.

Nice nice... hoping to get similar bits down the track

rgvlee · 14-05-2008, 08:22 AM

Found a few more parts

Powervalves fitted. Although you don't need to, i put a little bit of oil on them so they don't rub metal on metal to begin with. Also some blue thread lock on the powervalve retainers, a very small amount. At this point I'd cleaned and blasted the cylinders as well to get any remaining glass bead off them.

Oiled the big and small ends. Although it's been sitting for a while there was still a reasonable amount of oil in the cases.

Right cylinder on. Again a reasonable amount of oil used to make sure we're not dry on the first start up. This cylinder is the one with the chip in it so we will see how it goes. The other cylinder looks to have a similar fault in the same spot but hasn't chipped yet, so possibly a factory defect.

Left cylinder on, new head on the right cylinder

2 stroke bling

Couldn't resist... test fitted the new JL pipes

Few parts to order which I will sort today. A lot more cleaning to do, give the carbs a once over, fit water hoses, fit powervalve cables and assemblies... and so on. So will be a runner this weekend, but probably not on the road for a few weeks as I go over other things like tyres, brakes, chain/sprockets etc.

Cheers

L

Stratos · 14-05-2008, 08:25 AM

I have wood ... That looks amazing Lee, i cant wait to hear it with those pipes on!

ritza350 · 14-05-2008, 01:19 PM

damm those pipes are gor jus

....where's the powerband going to be now ?? as jl's are very much a high rpm pipe

nath · 14-05-2008, 01:27 PM

Nice work mate

Looks awesome..

speed3 · 14-05-2008, 01:29 PM

Good lord, that looks mint. Can't wait till I start doing up my teezer for the track. What sort of benefits can you expect from changing the heads?

rgvlee · 14-05-2008, 01:38 PM

i'd love to get 65 at the wheels with the heads valves and pipes, i think i'm more likely to get 60-62 though. Hard to say.

The jls are a kit copy and are are meant to give over rev to around 12500 with the right tune. Powerband will still start at 8k as that's when the valves open but it should come on harder at around 10k from what i've read. We shall see.

Seriously thinking getting a zeeltronics ignition and pv controller to make up custom maps... but i think i'll get her running first and enjoy it for a bit before pulling it apart again.

I'm not expecting huge gains from the heads as I am running stock inserts. It should run a lot cooler. When i've measured squish I'll have a better idea of what to expect. Certainly a better burn being straight plug and no more expensive gaskets.

There are reports of guys getting 5hp from the heads, similar from the valves and anything from 5-7hp for the pipes... i think that is very optimistic, 70hp+ rgv with bolt ons I find highly unlikely.

arwon · 14-05-2008, 02:27 PM

I have to agree on the optimistic horsepower, When i had one they were quoting 60 as awesome and somewhat acheivable.

It may be better to not run the full fairings cause it looks fast already...

thro · 14-05-2008, 04:11 PM

Anyone know of stephen horne who used to have the powerbandbikes website?

He was claiming 64hp from mostly tuning, pipes, porting and increased compression?

Think there's an archive of his site up somewhere.

BS, or achievable? Had a dyno sheet from memory... but we all know dynos can be manipulated to read whatever you like...

frazcat · 14-05-2008, 05:54 PM

man i need cash so bad....

wicked stuff man!

Laika · 14-05-2008, 06:03 PM

.. Thats looking awesome!

Stratos · 14-05-2008, 10:57 PM

Quote:

Originally Posted by thro

Anyone know of stephen horne who used to have the powerbandbikes website?

He was claiming 64hp from mostly tuning, pipes, porting and increased compression?

Think there's an archive of his site up somewhere.

BS, or achievable? Had a dyno sheet from memory... but we all know dynos can be manipulated to read whatever you like...

Porting is the magical word there Thro. Boltons do add a bit of meat, but where you take full advantage of it is when you start port matching and flowing the heads to match the flow dynamics of the new chambers and carbs. Its black magic.