The Bucket Foundry

[WilDun]

And in which case why has no one tried using a stone to give a unsmooth finish. You can get quite a nice flat but honed finished from that.

Or a file! - have read that as long as the passage is a dull "as cast" finish (still needs to be smooth with no ripples it seems)
Sometimes they use little tabs (vortex generators) on the wings of aitcraft to break up the boundary layer, with good results.
How about a sand blaster with nozzles pointing in a radial direction? - maybe I'm getting carried away here, we had come to the conclusion that casting was by far the best and cheapest way to go!
Makes me wonder how pipes get away with the ripples caused by welding or hydroforming! - but they seem to work ok.

[husaberg]

I just posted the pic cause i found it a clever solution casting is where it is out for the bigger stuff neil has all the gear to do the CNC but chooses to do it by casting that says something to me.

Neil can you talk us though the copy casting technique say for a 2 stroke crankcase would you do it or just start from scatch with a pattern.
I am thinking say like my NSR125 but modded to suit a rotary valve and the cylinder i have the patterns for?

[Flettner]

Can I see a picture of the NSR cases?
You don't want to run the case reed?
You are talking rear rotary valve?
How much different is the base of the barrel to the cases?

[WilDun]

I just posted the pic cause i found it a clever solution casting is where it is out for the bigger stuff neil has all the gear to do the CNC but chooses to do it by casting that says something to me.

HUSA,
I do understand that was just an example of what people had tried.
I would say that Neil has sussed out the best and most economical way of doing it, - he has given us a fair share of material to work on and I now feel that I should gather up that mountain of information and use it to get me up off my ass and suss at least some things out for myself from that!
I'm already working on it and I'm getting there (slowly) but I wouldn't have got far without some guidance from him and others. - wish I'd had all this info and had done it all when I was younger.
Never mind, hopefully I'll have a few productive years and with a bit of luck, one day (in the distant future of course), I'll have just tidied up the workshop after a good day, turned around to switch out the light and expire!!

[husaberg]

Can I see a picture of the NSR cases?
You don't want to run the case reed?
You are talking rear rotary valve?
How much different is the base of the barrel to the cases?

The picture ahould be above... by now i will try and find some inner pictures.

i have the dimensions for the cylinders vs the NSR ones from memory the NSR might be wider, "I should have brought a Suzuki RG125 there i said it MIKE"
but i got to thinking i am have trouble getting it to fit the frame will have to be modded the crank is giving grief needs 20mm pin has 24mm pin and needs destroking 4mm so why not make it fit by changing all the other stuff.. its a hopeless grasp i guess.

good god they are complex..

[Yow Ling]

Rg125/150 fit straight into nf4 single mount at rear just like mx engine

[husaberg]

Rg125/150 fit straight into nf4 single mount at rear just like mx engine

But what would Dave say, i can get the engine in no worries just need to do same plates.....
its rather ironic though that the cylinder stud spacing is closer to the Suzi though.

Can I see a picture of the NSR cases?
You don't want to run the case reed?
You are talking rear rotary valve?
How much different is the base of the barrel to the cases?

alright they are from memory the top left NSr125, some rotax?, the cylinder i have the molds for.
Bottom right Rg125, Rg500 and ke125 or visa versa.

[Flettner]

There is no easy way, like I tell my kids, there is no free lunch.
Either you take the cases somewhere and get them digittized or draw them up as a three D model, then machine from solid ( or machine a pattern ).

You could copy them into female halves ( using casting resin ), then cast off patterns in casting resin from these mold halves. Then cut and or stick on the bits you want ( rotary valve housing etc ). The problem with this is two, first you will have to block up all holes in the csaes, bearing housings will need tapered inserts and all edges will need to be checked for taper ( so it will come out of the mold ) also the surface will have to be smooooooth, two pot epoxy paint and lots of sanding. But it is possible.

It's time or money!

[husaberg]

There is no easy way, like I tell my kids, there is no free lunch.
Either you take the cases somewhere and get them digittized or draw them up as a three D model, then machine from solid ( or machine a pattern ).

You could copy them into female halves ( using casting resin ), then cast off patterns in casting resin from these mold halves. Then cut and or stick on the bits you want ( rotary valve housing etc ). The problem with this is two, first you will have to block up all holes in the csaes, bearing housings will need tapered inserts and all edges will need to be checked for taper ( so it will come out of the mold ) also the surface will have to be smooooooth, two pot epoxy paint and lots of sanding. But it is possible.

It's time or money!

I realised as soon as i seen the parts fiche just how complex the std cases are and that is was too much.
There is i see the problem it would be pretty much just as much work to make a 100 single as a v4 500....

[Yow Ling]

I got a spare rg if you want

[husaberg]

I got a spare rg if you want

My lady would not understand...............
Plus i have the other Honda stuff..... i think the path of most resistance should give me a warm feeling inside......

Where as another engine would see me outside in the cold......

[F5 Dave]

But what's the point of appeasing the wimenfolk and still being ghey by owning a *onda?

[husaberg]

But what's the point of appeasing the wimenfolk and still being ghey by owning a *onda?

Someone has to make me my sandwiches:-)

[HenryDorsetCase]

Te crank is giving grief needs 20mm pin has 24mm pin and needs destroking 4mm so why not make it fit by changing all the other stuff.. its a hopeless grasp i guess.

good god they are complex..

dont laugh at me if this is a stupid question but could you offset grind the crankpin to get the result you want?

[Kickaha]

dont laugh at me if this is a stupid question but could you offset grind the crankpin to get the result you want?

Not stupid at all, we did exactly that by starting with a bigger pin than we needed for my GN and which is a far superior bike to the one Husaberk is building because it actually runs and finishes races