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Author Topic: Project Assembly  (Read 18626 times)

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Offline 490 tez

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Re: Project Assembly
« Reply #60 on: May 22, 2009, 02:58:48 pm »
 ;D here is some cool machined stuff :D
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big bore two strokes rock!!!!!!!!

Offline Lozza

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Re: Project Assembly
« Reply #61 on: May 22, 2009, 04:19:16 pm »
I often say I how I don't know how I would get by without a lathe and a mill of sorts. Only problem is you tend to run out of capacity very quickly, then need to purchase additional tooling(I dunno if this is the case with 5 axis).I would estimate double the purchase price of a mill will be what you will spend with tooling.Lathes are not as bad but still the tooling is required to get the most from it.
HERE is a very good tool for the home workshop.Ji you need power feeds ;D
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Jesus only loves two strokes

Ji Gantor

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Re: Project Assembly
« Reply #62 on: May 22, 2009, 06:29:47 pm »
Oh what the hell.
I made another pair of the dividing washers out of stainless steel this afternoon.

Just to show how to get the job done if you forgot something like the taper I have set up the following example.
Remember "Tool Of The Week"
It was the Toledo collet slide hammer puller for wheel bearings.
Well if you forgot to put the taper on the washers you can make a mandrel which will take time or just select the right size collet and place in the lathe. The collet holds the washer while you turn the taper onto the face.

Pretty cool hey.

Ji
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Ji Gantor

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Re: Project Assembly
« Reply #63 on: May 23, 2009, 11:17:52 am »
I have now cleaned, buffed and polished the engine to a state were I am happy with only 2 weeks to go before CD6. I have started to attach the case covers to see how they look.

It is all looking good.
Shiny happy

Ji
« Last Edit: May 23, 2009, 08:47:07 pm by Ji Gantor »
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Ji Gantor

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Re: Project Assembly
« Reply #64 on: May 23, 2009, 11:23:34 am »
The triple clamps have now been cleaned, buffed and polished.
They are now ready to be placed on the frame.

Ji
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Offline maicomc490t

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Re: Project Assembly
« Reply #65 on: May 23, 2009, 05:53:05 pm »
Hey Ji - Come clean mate - you missed a few spots on the fins. Back to the Ajax and the tooth brush buddy !!!

The bike is shaping up to be one stunner - keep on keeping us informed.

Dave Mac  :D

BTW - What is your next project after the one we are seeing taking shape ?
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VAPOUR (AKA HYDRA / HYDRO / AQUA / WET) BLASTING AND GENERAL ENGINEERING 0416074750 (or) [email protected]

DUCATI Parts wanted esp 450 R/T and other early models inc V-twins

BULTACO M49 parts wanted

Offline paul

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Re: Project Assembly
« Reply #66 on: May 23, 2009, 06:05:03 pm »
ive got one he can do  ;) lol
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Ji Gantor

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Re: Project Assembly
« Reply #67 on: May 23, 2009, 07:22:29 pm »
I now have two steel and two stainless steel dividing washers.

Ji
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Ji Gantor

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Re: Project Assembly
« Reply #68 on: May 23, 2009, 07:26:45 pm »
The new plastic air filter box has to be fitted first into the frame before anything else so mark the holes and drill.

Ji
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Ji Gantor

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Re: Project Assembly
« Reply #69 on: May 23, 2009, 07:31:28 pm »
To get the air filter threaded rod to stand straight up inside the box I have to mill two nylon wedge shaped washers.
I am going to use 10mm thick millable nylon to make the wedges. I mark out what I require and with a scroll saw start cutting.

Ji
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Offline frostype400

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Re: Project Assembly
« Reply #70 on: May 23, 2009, 07:33:48 pm »
all looking great whats the best stuff to use when polishing engine cases barrel and heads that airbox looks trick thanks Michael  :)
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1971 tm400 and PE's

Ji Gantor

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Re: Project Assembly
« Reply #71 on: May 23, 2009, 07:34:29 pm »
I then place a belt sander upside down on top of a rubber mat so it does not move and sand the shape into the block that is required.

Ji
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Ji Gantor

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Re: Project Assembly
« Reply #72 on: May 23, 2009, 07:37:30 pm »
When I had the shape just right I then drilled a 6mm hole and deburred.
Deburr nylon with a stanley knife.

Ji
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Ji Gantor

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Re: Project Assembly
« Reply #73 on: May 23, 2009, 07:41:38 pm »
Very important.
To prevent the air filter nut coming loose and going through the engine drill a 2mm diameter hole through the threaded rod and twist some S/S safety wire.

Ji
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Ji Gantor

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Re: Project Assembly
« Reply #74 on: May 23, 2009, 07:44:41 pm »
With both nylon wedges shaped test fit in the box.

The threaded rod is now standing up straight  like it should.

Looks great.

Ji
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