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Post by henri on Sept 11, 2021 10:12:51 GMT
m200 001 by henri briggs, on Flickr . something interesting dropped into my lap last week , a quatt m200 cases,crank,barrel an a 34mm dell,pk gearbox ,not many of these puppies in uk an 1st one i'm building . m2002 001 by henri briggs, on Flickr . so a quick call to the "usual suspects" ,an madmax came up with a falc clutch an quatt "dustbin" exhaust ,an translated M200 "destructions" .interestingly in the extra notes max quattrini advises not to use a quick action throttle ,what a spoilsport .an thanks to daz of "lyrical" fame a set of 27/69 drt primarys dropped through my door. nxt up a quick order in with VE uk ,engine internals ,odds n sods ,etc , delivered nxt day as usual,well worth you guys checking them out for bits .ive a trade account ,rough trade some say ,but they sell to general public ,post for free ,always answer the phone an know there stuff . then the "italian job" ,a order in at 10 policci for stuff not available in uk ,an now the wait til that arrives ,bout 10 days fingers crossed .will keep piccys coming as i build .H
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Post by henri on Sept 11, 2021 10:14:34 GMT
oh ,an a quick order into simply bearings an bearings/seals dropped through my letter box nxt day ,for £88 .H
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Post by boreham on Sept 11, 2021 20:09:19 GMT
Will be very interested how this turns out!
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Post by henri on Sept 23, 2021 8:49:57 GMT
1st job on the quatt cases , check gear cable alignment on adjuster to cable wheel . m200 001 by henri briggs, on Flickr . not good at all ,seems its a constant on these cases ,if left the cables will rub on edge in use an probs not last long .so loads of measuring an thinking ,some weld up holes an re-drill an tap ,or threaded ali bar inserts an re-drill . m200 002 by henri briggs, on Flickr . during measuring i found cases are thicker an this shoulders higher than stock ,an adjusters are same height as stock .so am compenplating reducing height of shoulder so gear shaft can sit lower an wheel an adjusters line up . going to think long an hard on this one as there not my cases an there def not cheap or easy to replace .H
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Post by tzsteve on Sept 25, 2021 19:10:42 GMT
given what those cases cost that is just rubbish at every stage design, testing, manufacture, inspction.
i`ll bet there is a special gear linkage available at only £200
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Post by henri on Oct 4, 2021 6:41:03 GMT
its a constant TZ ,piaggio cases are usually out aswell . thurs 006 by henri briggs, on Flickr . 10 minutes with the "hot-file" an shoulders dropped 2mm ,5 mins putting a slight dogleg in linkage an gear selector sits down nice an turns freely with out being raised by linkage . thurs 001 by henri briggs, on Flickr . an we have a straight cable pull with no rubbing on adjuster or wheels edge .H
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Post by henri on Oct 4, 2021 7:21:15 GMT
whilst the "hot-file" was out it was time to tidy up some mould flashing ,not totally neccesary or essential ,just for piece of mind . BILD2292 by henri briggs, on Flickr . then in with the dedicated crimaz mounts ,an the water pump drive cover on ,nxt up its start getting bearings/primary in an check shimming on tree an gearbox.H
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Post by henri on Oct 8, 2021 7:46:03 GMT
rainy day meant outside playtime cancelled ,so got a day in on this earlier than expected .off to the playpen with a load of goodies . BILD2298 by henri briggs, on Flickr . bearings in the clutch side ,an gear fork in 1st ,shimmed with 2 wavy washers on the outside under wheel so it cant ride up an go out of cable alignment . BILD2299 by henri briggs, on Flickr . take down the bolt ends down on primary cush drive so they sit flush an wont rub on cases , loctite em and stake them too . BILD2300 by henri briggs, on Flickr . bit of a struggle ,tightest fitting ive ever found ,had to ever so slightly notch the case so basket had clearance on the bottom corner of clutch opening. an primarys are in . BILD2301 by henri briggs, on Flickr . kickstart an other crankcase furniture nxt ,breather/oil plugs/etc .as people have reported a kickstart eating tendency on these engines i chose a spanish steel kickstart ,so should last a while . BILD2303 by henri briggs, on Flickr . flyside nxt ,bearings in an then the tree ,had to bevel the edge of half moon cut out in cases 4th gear runs in ,tree wouldnt go in square to start it in the bearing before . BILD2302 by henri briggs, on Flickr . an cases together for the 2nd time to check ,free turning ,clearance between tree an kicker cog etc . BILD2304 by henri briggs, on Flickr . nxt trial fit clutch centre ,an houston we have a problem , rub/interference between centre an tops of cush drive allen bolts .because of tight clearances on kickstart quadrant an the groove in cases it passes through ,an close tree to kicker cog gap cant really shim them over . BILD2305 by henri briggs, on Flickr . out with engineers blue ,an 2 trial fits ,an 5 mins with the electric hot-file an we have a none rubbing centre . BILD2306 by henri briggs, on Flickr BILD2307 by henri briggs, on Flickr . after that excitement time to build the output shaft ,brand new pk gears an shaft ,an a DRT cruciform with the uprated 20bhp+ red spring .my luck was good an with my gadget went together 1st go .no playing chase the ball round the kitchen floor game this time . BILD2310 by henri briggs, on Flickr . an a final nervous moment to end the day ,for peace of mind check the quatt crank ,even though its new .an pleasantly chuffed its under a 1/4 thou in old money for runout true on the journals .an that could be from tolerances on my jig ,so happy with it ,nxt time fit the crank bearing flyside an then crank into flyside an gearbox an its cases together day .H
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Post by henri on Oct 8, 2021 7:49:01 GMT
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Post by henri on Oct 10, 2021 8:51:37 GMT
nxt was whilst bearings are heating fit the shaft and loose gears . BILD2323 by henri briggs, on Flickr . polymide caged bearings ,so didnt want to use a heat gun , so copied a idea by TZsteve , wax boiler/jam thermometer/2 stroke oil . BILD2325 by henri briggs, on Flickr . bring them upto temp an hold for 5mins for heat to soak in ,an then it just slipped onto flyside crank journal ,with a light tap with a pipe drift to ensure it was seated fully . BILD2326 by henri briggs, on Flickr . whilst the crank bearing cools ,heat cases upto approx 100degs ,an then crank an bearing just slips in ,hold it there with spacers an a fly nut . BILD2327 by henri briggs, on Flickr . whilst flyside case cools ,a thin smear of 3bond on mating face of clutch side ,assembly grease on tree,kicker shaft,output shaft ,an cases slot together really easily . BILD2328 by henri briggs, on Flickr . an then thanks to madmax for translated "destructions" case allen bolts torqued up to .8kg/7.8n/m-5.7lb/ft ,with a tiny drop of thread lock on each one .H
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Post by henri on Oct 10, 2021 9:05:14 GMT
nxt day its time to fit the primary cog drt , tab washer and loctite an 60nm . then on torqueing up clutch centre find at full torque a very slight rub on a cush drive allen bolt head .so another engineers blue/witness marks/file session an it fits ,no tab washer ,just wavy washer+loctite an 55nm. BILD2329 by henri briggs, on Flickr . then onto the falc clutch ,to find the wider slot in drt primary basket is too narrow for the wide tab on falc plates ,so another filing session an they fit in , BILD2330 by henri briggs, on Flickr ' as genuine xl2 covers are getting hard to find ,an sip ones can give troubles ,i went for a crimaz easy-clutch cover .an like everything ive had of crimaz it just fits out the box ,no messing needed .needs a 2mm spacer an 2 gaskets to clear the basket ,but i was expecting that with the taller DRT basket .H
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Post by henri on Oct 18, 2021 6:46:42 GMT
BILD2331 by henri briggs, on Flickr . the crimaz cover looks nice , an onto fitting the ignition an manifolds ,sorry for poor picture .will try an get another one . BILD2337 by henri briggs, on Flickr . i'd chosen a vmc billet flywheel an ignition system ,to find the boss around fly seal was too large for the vmc baseplate .ive found this before on piaggio cases an just relieved the stator plate to fit .but no way it was going to fit ,so i swapped base plate for a vespatronic one an the stator fits .the bad pictures trying to show the bottom of barrel stud shoulders/mouldings . the billet fly was never going to fit so a normal vmc fly was tried ,to find it rubs on the cases .so out with hot file an relieve cases back ,to find it needed to go back enough that the bottom of barrel stud needed to be filed down too . BILD2338 by henri briggs, on Flickr . after that "excitement" it was on with fitting reed an exhaust manifold ,an rough jet the carb .engines ready for the running stand now ,hopefully this week if weather holds .H
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Post by henri on Oct 27, 2021 8:07:42 GMT
BILD2359 by henri briggs, on Flickr . engine timed up to 23 btdc ,flywheel cowl fitted needs a 2mm spacer ,an fabbri m200 barrel shroud fitted ,needed to cut a plug hole in it as they come without .then it was outside an into the running up stand .H
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Post by henri on Oct 27, 2021 12:22:52 GMT
VID_20211021_152348 by henri briggs, on Flickr . 1st start ,an god its got some compression on it . flooding carb an wrong needle meant it wont tickover an doesnt rev clean ,but it starts an runs .H
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Post by tzsteve on Oct 28, 2021 10:02:00 GMT
I can't see the pictures on the last few posts but I can follow your text, As usual plenty of attention to detail, and nice work as usual,
The Allen bolts rubbing can be a problem I have found that if you use torx button head bolts they sit lower, but a decent Torx bit is helpful I found some nice A4 flange, Torx, button head ones on fleabay A4 is a marine, hi strength grade
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Post by henri on Oct 28, 2021 12:45:33 GMT
we both know the "devil is in the detail" , an theres a lot to consider .my nxt ones going to be fitting a pinasco "shot" clutch to a engine ,from what im reading its no walk in the park .H
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Post by tzsteve on Oct 28, 2021 15:56:58 GMT
I'm going to have a look at what those clutches are as I've never heard of them
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Post by henri on Nov 8, 2021 8:19:59 GMT
BILD2416 by henri briggs, on Flickr . made a start on getting engine into a frame to be dynoed ,a super lightweight space frame chassis i'm planning on fitting a LC aprilla barrel engine into later .to find some fitment issues as usual . BILD2431 by henri briggs, on Flickr . so a solid bar shock replacement made up , an frame cut behind mount so exhaust will fit ,an then to get on with cabling .the headsets a cosa base married up with a lammy series 3 clamp ,but i'd given away the plastic guides the tubes run in .an there pretty much unobtainable ,so shims made up from 1mm brass sheet , an px gear wheels used both sides to give a better throttle an gear selection .a pair of cheap chinese adjustable levers an its cabled ,just a throttle cable an front hydraulic to run now ,an its ridable .H
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Post by tzsteve on Nov 22, 2021 21:17:02 GMT
Nice
atleast you`re keeping the frame standard
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Post by tzsteve on Nov 24, 2021 17:28:14 GMT
H mate, looking at the ealier photos i notice you did not use a split bearing on the mag side of the crank any prticular reason for this?
and also the easeing of the clutch another part that did not fit (this is scooters all over)
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