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The "mule" Nanno's new naturally aspirated motor

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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: Hellgate » Sun Jul 01, 2018 11:54 am

Here's a few machine tools for you. Took these at Revival Cycles last Sunday.ImageImageImage

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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: nanno » Mon Jul 02, 2018 2:57 am

Drool-a-rama. I wouldn't mind a Bridgeport instead of my current mill. The lathe looks familliar, but I can't put a name to the mental image? (Southbend heavy 13? Regal LeBlond?)
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: Hellgate » Mon Jul 02, 2018 7:53 am

I've no idea the make. Next time I'm in their CNC room I'll take some photos for you. They've been kicking around the idea of getting 5 axial machine. They recently bought a scanner for 3D printing. Mainly to prototype quickly for a final handmade product. They currently use traditional wood ribs for building body work from aluminum such as tanks, tails, fairings etc. It's been interesting watching them develop their techniques over the past few years.

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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: nanno » Tue Jul 03, 2018 4:32 pm

In somewhat related news (and please yes, go ahead with pictures from the shop):
1) started working on the adapter to get my rotary table on the mill in working order today (this is sort of my Plan B to shorten the cylinders)
2) chasing a WW2 German production size mill. Not quite what I originally had in mind, but it's the right size and built as if they actually believed in the 1000-year-reich mumbo-jumbo. So it should quite easily serve me well for a few years.

Either way, progress is being made.
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: rantingsmith » Wed Jul 04, 2018 12:09 am

While we're looking at machinery, went to this place to pick up the Triumph Stag block my boss was having redone and overbored. I said to the old guy, I wish I new half of what you have forgotten over the years, there was block and cylinders all over the place V6, V8, V10, V12, Jag, Ferrari you name it there was a block being worked over or sitting finished or awaiting! Have a look at that 'swarf' tray...

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The Flying Anvil XV750SE '82 - Custom rear subframe, Bar end mirrors, New indicators, New tail light, 18" rear wheel conversion, KOSO speedo, lithium battery, custom wiring harness, clipons, modified SR500 rearsets, Lucas replica switchgear, K&N air filter, many parts powdercoated
XV920 '81- Watsonian Monaco sidecar tug project-work in progress - top end rebuild time
TR1.1 '81 Basket case project - Work in progress - Sepp Koch style frame chop plus refinement, XVS1100 jugs piston crankshaft conversion, nanno's 9 plate clutch conversion, BMW r850r rear shock, spoke wheels XS650 front & rear, twin 320mm discs with Yamaha Blue spot calipers, XT500 tank, twin Webber carbs, home built exhaust (hopefully) seat and subframe, footrest hangers...
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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: nanno » Tue Jul 10, 2018 12:39 am

Wee lil' update: Finished the cylinder shortening setup on the lathe yesterday and gave it a try - it works, but it's not practical as my lathe very politely tried to walk out the front door of my workshop. (i.e. it's just too light and starts oscillating) Which means I'll continue with building a small(-er) flycutter and do it on the rotab.

Expect some pictures on the weekend. (finally)

Oh and no new lathe. (yet)
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: nanno » Sun Jul 15, 2018 3:03 pm

Let's put it this way: six weeks. That's how long it took from first idea to the first actually successful testrun. And this is how it is supposed to work (tried on an already thrashed cylinder):

1) The cylinder is clamped between two T-shaped tophats and supported by a live center on the tailstock and in the foreground you can see what will later become the indexable boring bar during one of the first tests to see whether I could actually reach everything.
Image

2)As my QCTP took up some precious cross-slide travel, I had to fabricate a new toolholder...
Image

3) ... which in the end looked like this.
Image

Now all of this looked very promising (see last post), but as soon as the boring pushed against the workpiece, the live-center was in no way capable of supporting the cylinder. A bit more thinking and at least two attempts to flycut the cylinders on the rotary table of my mill had me re-think the lathe setup. (I am sorry, I*ve always been a lathe lad and less of a milling machine man...)

So today in the morning, I modified the backplate, fitted an old 6001 ball bearing and modified an old hex-bit to perform as an axle and finally everything is clamped down properly.

Image

I'll get back to the whole lot on Tuesday and will modified the chuck-sided tophat as currently it is slightly tapered, which is good for alignment, but even low force will make the workpiece shift between the tophats and cause it to tumble, even though this is already rather minimal and a slightly more hairy chested engineer would probably call it good enough.

There's a bit more on the fabrication of all the tools on the Blog: http://greasygreg.blogspot.com/2018/07/ ... ining.html

Additionally, I'll probably post some of the more (in retrospect) amusing failures of my fixtures in the upcoming days on my blog.
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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1979 RD250/R5/DS7-hodgepodge (in bits)
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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: faffi » Sun Jul 15, 2018 5:25 pm

Great ingenuity :cl:
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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: Hellgate » Sun Jul 15, 2018 7:22 pm

Nice work Greg! [emoji16]
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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: nanno » Sun Jul 22, 2018 1:45 am

To my own disappointment my fixture to shorten the cylinders just didn't work. Ever so often the whole lot starts to shift and as a result oscillate. I have an idea on how to do this in the future, but for now I really want to finish this engine and actually enjoy what I've built over the last year.

Image

One of the mistakes I made in the past was to mix up the front and rear sprockets, as I put them in as I found them in the engine (mind you I bought this engine partially disassembled) and as such the front and rear ones were mixed up. That being said, if you mark the teeth of the primary gear behind the rotor, you can very safely assemble everything. I wasn't entirely sure, so I pulled the roto and guess what: All tidy.

Image

With those mistakes tidied up, it was well about time to get back to head work. As I had to fit new valves anyway, I only deemed it appropriate to make them look pretty and polish them. (Opinions are a bit split on that, but I noticed less carbon buildup on polished valves, which is basically good enough for me.) The valves were polished with 120, 220, 400, 800 grit sandpaper.

Image

This is a relatively quick, but nonetheless messy, job in a lathe.

Image

As the stock valve springs create mad seat pressures, I decided to go with the softer inner springs out of a Virago 1100 to prolong the lifes of both rockers and cams.

Image

One of the things I really invested some time in was to blend the valve seats into the ports. The heads I had were exceptionally bad in this respect, as there was a massive lip where the valveseat was undercut.

Image

And that's what they look like now:

Image

I didn't take any picture of the new Viton valve stem seals, but in the past they have without a doubt been worth the money.

More pictures and a bit more on porting on the blog: http://greasygreg.blogspot.com/2018/07/ ... older.html
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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1979 RD250/R5/DS7-hodgepodge (in bits)
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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: faffi » Sun Jul 22, 2018 2:48 pm

Sorry to hear about the cylinder work not playing game, but you will likely sort it with time. Splendid work so far - hope to see a video when you start it up :cl:
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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: nanno » Tue Jul 24, 2018 1:12 am

It would be very rude NOT to take a video for you. (I'll probably post it tomorrow. Engine should be done and installed later today!)

After making some good progress on the engine earlier this week, there was one other thing that has been bugging me ever since I bought this bike. When I bought the bike I suspected that it had been in a crash at least at some point in its life. A few fork swaps and the fact that a rubber mallet was needed to install the upper frame in the lower frame mounts lead me to believe that the frame was buggered as well.

But before I could swan-dive into the frame swap, I decided that I had to tackled the heads first. Not very surprisingly I found a leaking valve cover. The reason it was leaking was due to a combination of really poorly executed thread repair or in other words: The threads were COMPLETELY on the proverbial p*ss.

Image

Image

Some fresh engine paint to make the heads look representable.

Image

Well my crash-free XS1100 fork legs, I've been running the last few years have turned out to be not quite so crash-free, one of them suffering from approx. 4-5mm (1/4") of runout.

Image

Next was trimming some no longer needed parts of the frame. I have a different breather setup than stock so that rear bit of pipe was no longer usefull to me.

Image

Image

The paint job was nothing to write home about, a coat of grey primer and then another one of satin black. I also painted the yokes, because they were looking a bit tatty and ever since I painted the lower one on the Turbo black I wanted to do the same on the mule. (Mind you a hot and humid 30 degree Celsius day is perfect for painting and even I can achieve some half respectable results!)

Image

Image

New steering stem bearings installed and frame and yokes are back in unison.

Image

And that's the new frame installed and among many other things, the rear subframe bolts align correctly and the airfilter base isn't bent anymore... Fun-fact: This frame is so straight (compared to the old one) that to my huge surprise, the forklegs fell back out, whilst I turned round to pick up the allen wrench from the workbench. The old yokes required some serious twisting and turning AND a rubber mallet to get them in and out.

[img]
https://3.bp.blogspot.com/-XyTe21K47ck/ ... 200581.JPG[/img]

And some damage you find along the way:

I've had charging issues for a long time on this bike, with one of the main reasons being this plug. It's been well fried since... no idea. Cleaned the contacts and filled it with di-electric grease and it should be good until the new engine goes in, which has a good plug.

Image

So you hear me going on, on just how badly bent the frame was, but then again, everybody can say that. See those brake pads? My old forks even required an extra washer to center the wheel in the forks.

Image

Looks just like before (almost)...

Image

... the old girl tracking straight is a nice bonus though. :cl:

Blog-Post: http://greasygreg.blogspot.com/2018/07/ ... -more.html
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: faffi » Tue Jul 24, 2018 4:14 pm

Wow, that's one very productive day :GJ:
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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: nanno » Wed Jul 25, 2018 12:58 am

Just a quick update - another two very productive days on Monday and Tuesday and the engine is ready for installation in the course of the day. Pictures will follow tonight or tomorrow, depending on when I get done.
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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Sex: Male

Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: Hellgate » Wed Jul 25, 2018 7:42 am

What's the configuration of this engine? I don't remember.
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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: nanno » Wed Jul 25, 2018 12:08 pm

TR1 cases, XV1100 rotating assembly, welded up heads, early cams, VM38 carbs.

Got stopped by a brandnew (yet still broken) Caltric solenoid. The second one out of this batch. I'll transfer the solenoid from the old engine over tomorrow. Also fixed a lot of other minor things that annoyed me in the last few years, so it was a very productive day, yet still I didn't get her done.
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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1979 RD250/R5/DS7-hodgepodge (in bits)
Sex: Male

Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: Hellgate » Wed Jul 25, 2018 1:32 pm

Nice.

Your solenoid issue reminds me of the 4 starter motors I went through in several months.

I'm curious to hear what you think of this configuration.
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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: nanno » Thu Jul 26, 2018 6:44 am

I'll just leave this here. And as you can hear by the hickups, this is truly the first startup and not something staged...

https://www.youtube.com/watch?v=l_dc9uN7Crs
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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1982 Yamaha TR1 Turbo
1977 XS 750 Sidecar
1984 XT500 4Valve (Austrian Tax saving edition)
1979 RD250/R5/DS7-hodgepodge (in bits)
Sex: Male

Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: faffi » Fri Jul 27, 2018 4:22 pm

It's alive :yahoo:
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Re: The "mule" Nanno's new naturally aspirated motor

PostAuthor: nanno » Sat Jul 28, 2018 6:50 am

It is indeed.

First 200km have been completed today. The hiccups came from a new albeit broken spark plug, which failed spectacularly today morning in the middle of nowhere. A set of new H*nd*-branded OEM NGK plugs was put in and now she purrs like a kitten. Unfortunately now the clutch cable snapped.

Guess there's just too much power and it tries to escape the engine where ever and when ever it can. :cl:

As it's waaaaaay too nice outside and there's a TR1 waiting for me :;: , you'll surely understand that I am really not in the mood for re-typing most of the last two blog posts, so I'll just put the links here for now and edit them in later this weekend.

http://greasygreg.blogspot.com/2018/07/ ... ngine.html

and

http://greasygreg.blogspot.com/2018/07/ ... ngine.html
http://viragotechforum.com/viewtopic.php?f=12&t=43227 - Nanno's accumulated findings (and blatant show-off) - infos on my TR1's, my performance and reliability mods and a bit of show-casing of the stainless steel exhausts I build

http://greasygreg.blogspot.co.at (My blog - Greasygreg.blogspot.co.at)
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nanno
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1977 XS 750 Sidecar
1984 XT500 4Valve (Austrian Tax saving edition)
1979 RD250/R5/DS7-hodgepodge (in bits)
Sex: Male


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