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Post by Wayne Miller on Dec 23, 2009 21:24:28 GMT
Hi All,
Decided a few months back that I was going to do a rotax conversion but it got side stepped and I did a falc rotary instead. But as the dark nights have drawn in I got a little restless and and decided to continue with the rotax conversion.
So just got the casings back from the welders and realised that I forgot to tell him that the inlet needs welding shut too. I also need part of the area built up to accomate a mounting point for the packer.
Anyhow the casings arent looking that bad now and just need dressing. I'll see if I can get some piccies up on here later but Im off to wrap some pressies now whilst my missus is out and the little uns in bed.
I hope to start on the packer plate on Tuesday / Wednesday so I'll post some more pics then.
Until then a Merry Christmas to all ;D
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Post by tony on Dec 25, 2009 0:55:06 GMT
good stuff mate.. keep us all posted.. and just make a 'blank' plate for the inlet port. Use dome head allen bolts and they will clear the new packer plate. No need to weld it.
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Post by Wayne Miller on Dec 26, 2009 22:11:31 GMT
good stuff mate.. keep us all posted.. and just make a 'blank' plate for the inlet port. Use dome head allen bolts and they will clear the new packer plate. No need to weld it. Hi Tony, I was originally going to make a blanking plate for the inlet but I want to add extra support for the packer to strenghten it and there doesnt seem to be enough meat around the inlet at the moment. Im taking the casings etc round a mates workshop on Tuesday so I'll see what he thinks when Im there, pics to follow to show you what I mean ;D |
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Post by Wayne Miller on Dec 26, 2009 22:31:36 GMT
Pics of top of casing to show additional welding for transfers and additional mounting points for bolts to help secure packer plate. The casings are not warped there just not bolted together  Pics of side of casings to show welding for transfers  Other side of casings  Welding around the inlet, I may be adding more weld and filling in this area as there doesn't seem to be enough meat on it yet to secure a bolt to  Old polini gasket, I'll be using this as a template for the 12mm packer  The Aprillia gasket showing the huge difference in size to the Polini, I'll also be using this as a template for the packer  [/url] As you can see there's too much weld in places and not enough in others but as its the first time that I've done this and the first time my welders done this too, its not a bad job. Next job is to remove the studs and excess metal from casings and start work on the packer plate More pics to follow . . . . . . . . |
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Post by tony on Dec 26, 2009 23:41:16 GMT
ok mate.. were those cases welded whilst bolted together?
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ash
Automatica
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Post by ash on Dec 26, 2009 23:53:33 GMT
how much did he charge to weld that for you?
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Post by Wayne Miller on Dec 27, 2009 9:10:40 GMT
ok mate.. were those cases welded whilst bolted together? The majority of it was done with the casings together but some of it was done with the casings apart. I told him not to let the casings get too hot so hopefully the wouldn't have warped  |
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Post by Wayne Miller on Dec 27, 2009 9:12:25 GMT
how much did he charge to weld that for you? It took the guy about 2hrs to do this and I didnt know him, although he was recomended as hes welded quite a few lammy cases for a mate. So £50 was the price we agreed. Anything that needs touching up he'll do for free |
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Post by unreliablesc on Dec 27, 2009 11:56:35 GMT
keep us posted mate!
when are you having the casings milled?
are you going to CNC the packer?
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Post by tony on Dec 27, 2009 12:27:21 GMT
Ok.. if were me I'd bolt them back together and 'stress' relieve the cases by heating them very hot. Let them cool and see where you are. Maybe get them warm before you bolt em tbh. They do look warped to me. But they should go back ok.
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Post by Wayne Miller on Dec 28, 2009 12:56:12 GMT
It must be the pics Tony, the casings are still a matching pair and dont seem to have warped to the eye ;D
The packer wont be CNC'd just using a lathe, a pilar drill and good old fashioned dremmel ;D
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ash
Automatica
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Post by ash on Dec 28, 2009 18:19:27 GMT
could you pm me the some contact details for the welder cheers
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Post by Wayne Miller on Dec 28, 2009 18:42:38 GMT
could you pm me the some contact details for the welder cheers The guys name is Martin and his contact details are below: Marton Engineering Ltd Unit 2 Albany Court Market Harborough LE16 7QP Tel: 01858 434435 Chalkie from Replay Scooters uses him all of the time for all of his ally welding work. It was Chalkie that recomended him to me |
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Post by tony on Dec 28, 2009 20:40:28 GMT
It must be the pics Tony, the casings are still a matching pair and dont seem to have warped to the eye ;D The packer wont be CNC'd just using a lathe, a pilar drill and good old fashioned dremmel ;D Good stuff then. |
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Post by Wayne Miller on Dec 29, 2009 12:02:51 GMT
The casings are now back with the welder having a plate put over the inlet and some weld built up on top to accomadate a bolt to help secure the packer plate. Once this has been done its off to a local engineering company to have the gasket face and excess weld machined flat. He will also put all of the countersunk holes for both sets of studs into the packer plate ie one set of holes to bolt the packer to the casings (the usual four plus four more to help stabilise and add strenght) and one set of holes to bolt the barrel to the packer as well as creating the hole for the barrel to slot into. Then its back over to Replay scooters where Chalkie will finally match the barrel to the packer etc and cut out the transfers on the packer and scoop out the transfers on the casings. Then its a matter of putting it all together and sorting the gearing out. Then its off for an exhaust where I'll discuss which rev range to open and close the powervalve at (I'll also discuss the possiblility of increasing the bore and a poss retune on the barrel)
I just need the time and the money but all good things come to those who wait ;D
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Post by dayle1991 on Dec 30, 2009 22:39:00 GMT
what exhaust are use going to use? will this engine be for the road?
;D
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Post by Wayne Miller on Dec 30, 2009 23:01:11 GMT
what exhaust are use going to use? will this engine be for the road? ;D Im hopefully going to contact Charlie at performance tuning (Its only 10 mins away from me ;D ) and if hes not too busy get him to tune the barrel and make a pipe to match ps. yes its for the road |
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Post by Wayne Miller on Dec 30, 2009 23:28:39 GMT
I get my casings back from the welders on Tuesday so Ive scrawled on a bit of paper (Very technical ;D ) ready for the local engineer to machine my packer, its a bit vague but he should get the drift once Ive waffled in his ear for half hour. Scrawlings below, its gonna look like a piece of swiss cheese when its finished: ps the bits in black are the bits that Chalkie is doing with his dremel, rather him than me ;D  other pics of 12mm packer and gaskets, the engineer will also be getting these  the 12mm packer and the barrel, the engineer will be getting this too  Another thing that Ive got to get sorted out is a new route for the coolant. Usually the coolant usually passes into the casings before exiting back out towards the radiator through the hole above the transfers. This hole will be blanked off by the packer...........please see other pic below  pic below shows a square area above the 'aprilia' logo this is where i will be creating a new exit for the coolant. the exit will be in the form of a plastic elbow facing towards the front of the scoot  Its all good fun and looks like things are about to start happening. I'll post more piccies when things progress. PS I sending my crank to Wolle @ Scooter & Service tomorrow as I cant get hold of the right rod so hes going to modify a rotax rod to fit for me and as hes the one who's told me how to build the thing its only fair that he gets payed somewhere along the line. Ive got other bits coming from him soon so he's being well looked after  Cheers Wolle |
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Post by tony on Dec 30, 2009 23:39:43 GMT
Good choice of tuner and pipe builder. |
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Post by Wayne Miller on Dec 30, 2009 23:57:55 GMT
Good choice of tuner and pipe builder. Yup, If you want a good job doing the go to the best |
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Cheers Wolle