The Bucket Foundry

[TZ350]

That is very clever stuff. ....

[WilDun]

I've been working from home too long, you are right, these drums 60L are not as plentiful as they once were. I've found a drum to use but it's not a 60L one
starting to learn how to use this gear hobb, spur gears only at this stage. Still trying to fathom the calc's for spiral tooth.
I now have cutters for 1 to 3 module in .25 steps, just right for building gearboxes. Seen here is 2.25 Module.

Thanks for looking for a drum, I am still going to persevere with my sheetmetal monstrosity, but if you did actually obtain the drum and it will not be of use to you, I would still be interested.
Yesterday I obtained a small crucible (about the size of a large teacup) which I intend to use for the small melts I will be starting off with so I need to build a smaller furnace for it (should be much more economical to use) and apply the knowledge I have gained in trying to make this bigger one!

BTW I worked in a gearcutting shop for a few years coming up to my retirement five years ago, (not actual gearcutting more turning).
The guy who owns the shop is an avid experimenter like yourself
Think he might be a subscriber on this forum too.

[WilDun]

Starting to learn how to use this gear hobb, spur gears only at this stage. Still trying to fathom the calc's for spiral tooth.
I now have cutters for 1 to 3 module in .25 steps, just right for building gearboxes. Seen here is 2.25 Module.

It would seem that the engine will be turning backwards and I guess that the major thrust side of the piston will still be on the back wall and transfer port.
Is it possible that if the major thrust side of the piston was on the exhaust port side, would there be any benefit? or would that be likely to cause wear problems?
I do seem to remember MZ trying this on their earlier racers, ie with the cylinder reversed and forward rotating crank, (not with an idler as you appear to be using).

[Flettner]

The engine will be turning backwards, the exhaust points rear, thrust is at the transfer side. Part of the reason is to keep the exhaust away from harm and part to see how the bike "feels" with handleing. This is the engine that will be EFI into the cylinder, throttle done by the slide over the RV, controlled by the ECU. I have a few other ideas on porting I would like to try on this setup also. Vairable ( on the fly ) crankcase volume will also get a tryout. Ethanol will be the fuel.
Lots of ideas to try, just need to finish it! I'm adjusting the water core mold at the moment to be able to fit a power valve blade ( adding metal to the casting through the water core ).

[WilDun]

The engine will be turning backwards, the exhaust points rear, thrust is at the transfer side. Part of the reason is to keep the exhaust away from harm and part to see how the bike "feels" with handleing. This is the engine that will be EFI into the cylinder, throttle done by the slide over the RV, controlled by the ECU. I have a few other ideas on porting I would like to try on this setup also. Vairable ( on the fly ) crankcase volume will also get a tryout. Ethanol will be the fuel.
Lots of ideas to try, just need to finish it! I'm adjusting the water core mold at the moment to be able to fit a power valve blade ( adding metal to the casting through the water core ).

Interesting stuff - looking forward to seeing how it all pans out, seems to make a lot of sense.
The two stroke isn't dead yet, as you can see in the British championship with the little 125 machines still up there, battling with the 250 four strokes!
I may try out some old ideas I thought up in the past but have to control myself and get the foundry in action first, one step at a time otherwise I'll get nowhere!
Still interested in the four stroke as well though.

[husaberg]

Hello Neil
I just noticed that most of the F1 rules for events in NZ do not seem to specify that the engines for up to 760cc twins or 3's need to be production based.
What is the stoke of the 1050 triple going to be.
The two stroke 4 are pegged at 500.

[Flettner]

Bore and stroke are 80mm x 70mm, yes it could easily be made into a 750cc, same stroke smaller pistons.
Husaberg, I'm building up a set of cases at the moment, horizontal split, to suit the sleeve cylinder ( and perhaps an FOS type cylinder as well to try). It's case reed.
I'm not using the CNC at all, old style just building it up from wood shaped pieces. You might be interested? I'll post some pictures as I go, just felt I needed to keep things moving on that front.

[Flettner]

Horrizontal split case reed.

[husaberg]

now that is clever I always get confued on the cad with zoom in and out, I get lost, plus I draw shit, (son looked at my V3 tonight and asked if it was an elevation drawing of our house)
With this approach in scale and in real 3d . you are a genius Neil......you may object but seeing the simple way is genius.

I seen something with casting bronze statue something the other day they dipped a wax male in a ceramic coating (much like a glaze used in pottery I guess) it was (I assume) to get a better surface finish with the lost wax casting and maybe allowed a tighter ramming do you know how this works and what they use for this witchcraft?

[Flettner]

Isn't the pattern made of wax, often hand carved, then dipped in a ceramic slurry many times ( time to dry after each dipping ) then wax melted out, bronze then tipped in. I think the reason is for fine bronze work. Ok of you can carve one case out of wax, if you cock it up you start from scratch!
Wood is soo good to work with, if you cock it up just glue a new bit in. And bondifil can cover much roughness!

[husaberg]

Isn't the pattern made of wax, often hand carved, then dipped in a ceramic slurry many times ( time to dry after each dipping ) then wax melted out, bronze then tipped in. I think the reason is for fine bronze work. Ok of you can carve one case out of wax, if you cock it up you start from scratch!
Wood is soo good to work with, if you cock it up just glue a new bit in. And bondifil can cover much roughness!

I was just wondering how it works, I was assuming the wax was melted out with the molten metal but your explanation makes sense. I must have missed the melt it out bit........
Yes making a crankcase out of wax does not sound like fun. imagine if it got too hot.........

[Flettner]

I save all the old wood things being thrown out like old bed frames etc, all good dry wood. This pattern is largely made up from my mothers old ironing board, I knew it would be useful for something one day. Five minute epoxy, a lathe and sand paper are most useful.

[WilDun]

Yes making a crankcase out of wax does not sound like fun. imagine if it got too hot.........

Pretty hard stuff that wax they use, doesn't melt that easily but it is quite brittle!
I think it is better to make a wooden or plaster mould to cast the wax pattern instead of trying to machine it, a lot of extra work just to make a one or two off!
Yes, the wax is melted out and re used. (plenty of stuff on the net and You Tube I would think - maybe just punch in 'lost wax investment casting').

The wax (investment casting) is very good for obtaining a dimensionally accurate and good looking finish though - I have seen a lot of stainless steel castings which I have had to machine in the past, done using this process - great looking castings, minimal machining required.

In the case of things like these crankcase patterns, the old tried and true sand moulds work fine though.

[WilDun]

Neill,
I have got to admit that I am having trouble understanding the porting layout on that cylinder casting though, especially the exhaust. - is that the sleeve valve job?
If I keep plugging away, no doubt I will figure it out, but maybe it would just be easier if you could explain!

[Flettner]

Yes, thats the sleeve cylinder, thought I need to run it, see what happens.
The same crank case will accept a copy of Frits's FOS cylinder, I will have a go at that too.
AND it all fits into my spare YZ250F frame. Good, if it ever works.
I have some other cylinder types in mind that also will need the same crank case. YZ 250 twostroke clutch and gearbox.