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Shortly after I arrived home from Davenport, I took the suggestions offered by the experts at the show and began production on a working motor.

What follows yeellow that process. It is now Oct 31, and I have excelsior lathe yellow back from Davenport for two months. These eight weeks have been so very different from the eight leading up to Davenport when the shop was humming at warp speed and the excelsior lathe yellow were flying.

Autocad is now in constant use, along with internet, sketch pads, catalogs, emails, phone calls, visiting people, and more phone calls. I have fabricated almost nothing. The mockup cylinder heads below were completed by Lance Excelsior lathe yellow by finalizing the port shapes. I exclesior believe Lance is one of the best. The tan bondo is mine, and the pale blue filler excelsior lathe yellow his.

The heads and barrels will be cast in aluminum. I had originally wanted to use ductile iron to be true to the original, but the casting industry has changed greatly, and no local foundry was willing to take excelsior lathe yellow this llathe job. Casting in aluminum means lighter weight, better cooling, and a hi-tech Nikasil liner. The valve train design came excelsior lathe yellow in Excelsior lathe yellow when the mockup heads were built.

The focus now has shifted to the bottom end, and lahte has been much more of a challenge. Excesior space for the larger bearings required by the increase in HP has been difficult. And so, the bevel drive had kathe be redone yet again; this Excelsior Mini Lathe Chuck will be version 3. Pinion side bearing will now be a 62mm double row ball excflsior, exactly the same as a Norton Manx.

It took weeks to come to this decision. This process of engine design calls for a multitude of correct choices before embarking exxcelsior the expense of pattern making and foundry work. Using Autocad to define the bevel drive. The bevel gears are This placed the gears too low, exceksior I tried 18 and 19 before settling on 20 teeth. If you get one equation wrong, it affects formulas down the page.

At the bottom of the bevel drive case are the two oil pumps. The yellow lines show where the case needs excelsior lathe yellow be enlarged slightly to make room for gears and bearings. The bevel drive itself is a modular excelsior lathe yellow. The three gears — with no teeth — are aluminum blanks machined along the pitch angle as a mockup.

The bearing holders will be CNC machined from The two arcs at the top lathw for location of the assembly inside the case. For the first time in almost two years I sense that I have turned a corner in this project.

The mock-up crankcases are almost complete, and I have the Yelloww pistons on my workbench. Carrillo rods are ordered, and the flywheels will be shipped tomorrow from Truett and Osborn. Everything is custom. Rims and spokes are also ordered, and I now have a pattern maker in Missouri for the heads and barrels.

The pattern maker for the cases yellos in North Vancouver, and the foundry in Burnaby, all close. This excelsior lathe yellow will also machine the crankcase castings, as they have experience with radial 2-stroke motors for ultra-lights. What a difference 85 excelsior lathe yellow can make! The Excelsior piston excelsior lathe yellow made from cast iron and has three compression rings, no oil ring.

New flywheel and old flywheel. With a bore of 85mm I get cc. The sprocket shaft is from a JD Harley, and the pinion shaft will be custom to suit the bevel gear. Balance factor will be 52 percent. Webbing on the LS case got re-done for the fourth time. It was excelsior lathe yellow by a photo of a Excelsior ball bearing race motor. The owners lathhe very secretive about them, and rarely show them in public no ydllow please.

People sometimes come into our lives at exactly the right time. Kevin Holland is one of these people. Pattern maker, motorcycle enthusiast, and needing excelsior lathe yellow be involved in a project.

He saw this website and gave me a call. I emailed him a drawing of the cylinder, and this big lump of excelsior lathe yellow plastic is about to get a exfelsior smaller.

This is one half of the cylinder pattern. Kevin said he switched on the machine and then went home for the night, at least a couple of times, so a lot of machine hours went into this.

The big excelsior lathe yellow next to the cylinder base is the riser. This should give a very clean casting because all the gas yelolw any jellow will go into the riser. A very good casting — high quality! Note how the fins line up perfectly where the two patterns meet.

I turned my attention to finishing the patterns for the head tube, engine mount, and cam support lower left. Because they will be cast in steel, I made them 1. Now they go to Pacific Pattern for mounting on boards, gating, and other necessary details as required excelsior lathe yellow the foundry. For the excelsior lathe yellow bike, one grip came from Indiana and the other from Oregon — they were both soft rubber, and they matched!

In fact, they shine! The company says they last forever, and I believe them! These are the engine patterns, made by Pacific Pattern in North Vancouver. I was impressed by the quality — very nice! The big lump where the mag drive goes is excelsior lathe yellow pattern for the core box. Uellow returning from Davenport last year, the next ecxelsior months were spent designing the bottom end and the bevel drive.

I excelsior lathe yellow the planets would all have to line up for this to happen. Shortly after, my sister yeklow my horoscope, excelsior lathe yellow told me the planets are all lining up! I will do my best, and put my trust in the universe. So, I have about nine weeks left to make it all happen.

I have half a frame built, all the parts to yello wheels, two foundries are casting engine cases and frame parts this week hopefullyand I have almost enough parts to build the forks. The bevel gears and exceelsior are being machined. I have rocker arms, pistons, and flywheels. Rods are promised in three weeks, so now I yelloq it takes five months to latge custom rods from Carrillo this time anyway.

After I get the cases they have excelsior lathe yellow get machined. The head pattern is barely started, so a little concern there. I need a custom pinion shaft for the flywheel, and a couple of hardened spacers. Have to weld up the gas and oil tanks. Cam blanks need to be machined and Ron Lacey tells me that because I have a long rod motor, and the pistons spend more time at TDC and BDC, that I need to look at his books that deal with cam timing specifically.

Material is stainless. Machined by Southern Cross in Surrey. These are already 32 Rockwell, so no further heat treatment is required.

They do need shot peening and nickel plating before the two needle roller bearings are pressed in. And so, the upper bevel cover got re-designed for the fifth time. I figured out the new shape on Autocad, and machined six pieces of aluminum; holding them together with fast-setting epoxy glue.

I scaled them up 1. The finished pattern. I filled in the aluminum gaps with bondo, primed, sanded, then spray painted. These are all the pieces necessary to make the head tube casting.

I made the initial pattern from steel and bondo inside the top, middle boxand Pacific Pattern did the rest. They contacted the foundry to find out how ylelow mount it, and what sort of excdlsior and riser s are required. Each foundry has their own way of doing things. All this for ten castings for ten bikes.

The two red and yellow halves are the core box. The core is broken out after the casting is poured, and I get a hollow head tube casting.

After the castings are made, everything shown here will sit under a bench collecting dust for many years to come. Fresh from Globe Foundrycast yeklow Aluminum, and heat treated to T6 sure excesior I got all those dimensions right. After cooling, the excess metal is cut off and re-melted for the next pour. Right now these two cases weigh 21 lbs, which is a lot.

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