The Bucket Foundry

[Flettner]

Bastardized FOS water jacket. 120 degrees each, fixture in the dividing head.

[speedpro]

So many places for water to leak from. Well it would if I was making it.

[Flettner]

So many places for water to leak from. Well it would if I was making it.

Nothing a tube of silicon wouldn't fix

[speedpro]

Worked on my FZR twin to keep the oil in

[Flettner]

FOS cylinder fits the water jacket now, 8mm cylinder movement. I guess machine some exhaust ports next (x3).

[ken seeber]

Jeez, just imagine a carburetted 2 stroke being able to 2 stroke at idle.

I call it FLOS........FLettner Optimised Scavenging

[polinizei]

Final printing job's took about 6 days.

[ken seeber]

Polinizei,

These are just beautiful. Clearly you have put a lot of thought into the design, particularly with part lines and the changeable inserts for the exh and transfer passages giving you the capability to make easy and accurate alterations. I have a couple of questions:
1. Did you use any support structure for the printing?
2. The finish is superb for an FDM. What Z increments did you use and is it PLA or ABS? I think you might have told us before...sorry
3. Not exactly sure what the little black pieces are for, these are on the inside of one of the transfer boxes

Really great. Please keep us posted on the rest of the core boxes for the outside. Thanks a lot.

[polinizei]

I use Z-Ultrat filament.
Resolution 0.09 for the ducts and 0.14 for the other prints.
Support is standard 20°.
Placement of the print is importend, to reduce support material an get smooth surface. In this case I did a lot of testprints...
The two little black parts are for centering and parts of the big core boxes. They are removible for easy adjustems in case of printing tolerances and machining the core box bore withe a lathe.

[Flettner]

Production run of cases to suit the YZF 250 frame. Destined for several different cylinders to test. Seen here the bastardized FOS with vairiable port timing, 8mm cylinder movement.

[Flettner]

100cc FOS looking down one of the exhaust ports, open and then shut 8mm (low speed running). Still need orings to seal off exhausts and also from crank case to water cavity.

[husaberg]

100cc FOS looking down one of the exhaust ports, open and then shut 8mm (low speed running). Still need orings to seal off exhausts and also from crank case to water cavity.

You make a good case for the design.......................

[TZ350]

100cc FOS looking down one of the exhaust ports, open and then shut 8mm (low speed running).

Very clever and very, very interesting, FOS100.

[jhenise]

Howdy all, I have been following all of Neil's amazing work on here for about a year. We finally got to talking and he asked me to post some photos of my pattern making and sand casting work on here. Michael Moore posted photos of patterns I made for making air cooled heads on this thread a few pages back.

We don't call them buckets here in the USA, but I build and race what qualify as bucket racers here in California.
The machine I currently race and develop is a rotary valve 175, based on the Kawasaki F3 and F7, that I call the "F37" you can read about it here:

http://www.highwaymanbikes.com/the-h...ge-road-racer/

As it turns out the cylinders undergo catastrophic failure after a few weekends due to a much to weak mounting flange.



So i have decided to solve the problem with a new casting, and while i am at it, I will improve the transfer passages and go to a nikasil bore...

I have started the pattern making process for the mew jug that need to be on a running engine by March to race!

Viny casting of the old ports for reference...


I love CNC "paper tooling" I use it as templates to make many many things in my shop....


Here is how "paper tooling" models the old cylinder ports and deck...


Here is how paper tooling show where the improved ports need to be...



The new ports are made with clay, just like in grade school art class!


Comparing new streamline transfer passages to the old...


Smoothing out the inner wall...


Finished port patterns...



Now I am molding the ports in silicone so i can cast hard copies in urethane that will be used in the next steps of the pattern making process...



more to come...

[Muciek]

Great project!! I certainly will for wait for update. I see This cylinder does have wide stud pattern wouldn't it be better to make 5 ports instead of 3? Since You want to cast it You can add them without welding and tons of grinding. I know it will be more work but results (power and powerband length) should be way better, and all the info about ports it's here and in ESE thread and there are alot of friendly people who can help with port sizes and angles.