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Thread: The Bucket Foundry

  1. #4816
    Join Date
    25th March 2004 - 17:22
    Bike
    RZ496/Street Triple R/GasGas/ etc etc
    Location
    Wellington. . ok the hutt
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    18,230
    Jezzuz were you working for Steptop and son? Places that do my work for work are constantly filling up warehouse with new machinery. Pallet loader 5 axis, laser the size of, well its pretty big. Hate to see thier overdraft but
    Seems to work
    I've been told. Dreaming`s free.
    Think I'll go, back to sleep.
    Everybody listen, voices in my head
    Everybody listen, do yours say, what mine says?

  2. #4817
    Join Date
    28th August 2015 - 00:01
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    1975 Hodaka Wombat
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    Eugene, Oregon, USA
    Posts
    233
    I'm slowly progressing on my opposed piston engine. I think this is the final design for now. The next step is to make the various parts and assemble everything with a plastic, 3D printed cylinder and pistons. If that looks good, I'll get a metal cylinder cast or 3D printed. Below are some of the pictures. I tested various exhaust leads holding everything else the same. Low leads boosted bottom end at the expense of over rev. Higher leads did the opposite. I think a 4 degree lead is the best compromise.

    Lohring Miller

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  3. #4818
    Join Date
    12th March 2010 - 16:56
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    TT500 F9 Kawasaki EFI
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    Hamilton New Zealand
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    Quote Originally Posted by F5 Dave View Post
    Jezzuz were you working for Steptop and son?
    You might well wonder.
    Maybe Ill just go and drive tractors, we are rurual after all.

  4. #4819
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    20th January 2010 - 14:41
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    husaberg
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    The Wild Wild West
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    10,647
    Not foundry but interesting


  5. #4820
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    24th April 2016 - 19:07
    Bike
    2001 zx9
    Location
    bop
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    77
    Quote Originally Posted by Flettner View Post
    You might well wonder.
    Maybe Ill just go and drive tractors, we are rurual after all.
    Nah that won't work - after a few hours you'd start to get bored and your mind would start wandering to a triple crank vee 5 with a common combustion chamber... just declare monday to wednesday is for paying customers and stick to it. the rest of the week would be yours with a clear conscience then...

  6. #4821
    Join Date
    12th March 2010 - 16:56
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    TT500 F9 Kawasaki EFI
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    Hamilton New Zealand
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    Jimmy,

    So I have decided to get back to the 360 mk2 TPI project largely because its all been paid for. Just needs the time invested to dyno and tune. Got it fired up last weekend, 'plastic bottle injection' , Ignitech works. Now to sort the LINK, that will no doubt be time consuming.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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  7. #4822
    Join Date
    24th April 2016 - 19:07
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    2001 zx9
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    bop
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    77
    Great work! but we don't want to find the best inventors in the soup kitchen...

  8. #4823
    Join Date
    25th March 2004 - 17:22
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    RZ496/Street Triple R/GasGas/ etc etc
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    Wellington. . ok the hutt
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    Especially if he's serving. Those knees would put me off my soup.
    I've been told. Dreaming`s free.
    Think I'll go, back to sleep.
    Everybody listen, voices in my head
    Everybody listen, do yours say, what mine says?

  9. #4824
    Join Date
    12th March 2010 - 16:56
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    TT500 F9 Kawasaki EFI
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    Hamilton New Zealand
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    It fired up with the LINK, ran for about 30 seconds then stopped. Wouldnt restart apart from a few pops from time to time. Turns out the rotary valve had slipped around. So next weekend we will have another go and possibly a better valve drive arrangement.

  10. #4825
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    12th March 2010 - 16:56
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    Hamilton New Zealand
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    As I thought, the nut on the end of the crankshaft was loose. Nothing damaged, but Ill make up some special tools to hold the crank gear as I torque it up, tight.
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  11. #4826
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    20th April 2011 - 08:45
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    Raalte, Netherlands
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    Quote Originally Posted by Flettner View Post
    As I thought, the nut on the end of the crankshaft was loose. Nothing damaged, but Ill make up some special tools to hold the crank gear as I torque it up, tight.
    Some special tools? What could be easier than fishing a gear out of your junk box and use it to block the primary transmission?
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    You can of course also shove a hammer handle or a broom stick into the exhaust port

  12. #4827
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    20th January 2010 - 14:41
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  13. #4828
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    12th March 2010 - 16:56
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    Hamilton New Zealand
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    Quote Originally Posted by Frits Overmars View Post
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    You can of course also shove a hammer handle or a broom stick into the exhaust port
    Aww, Frits, yes Ive done that before but a bit rough though.
    A much better idea is a tool like this. This one quickly made to hold the crank gear by all its teeth for the F9 Kawasaki, spread the load.
    Tightening load goes only from all the teeth to the nut. This way some serious torque can be applied.
    CNC makes a quick and simple job of it.
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  14. #4829
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    9th September 2013 - 06:34
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    AM6 70cc pitbike
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    Suomi
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    7
    I posted last year about a cast iron cylinder that I cast. I finished it some months after that and it worked very well. Gave 11 wheel hp with 3 transfer ports and a pre-worn piston.





    Now I'm working on a new cylinder, this time 50cc and now trying to get the best duct design possible. I have used transfer duct radial angles published by Frits in his scavenging concept picture. I hope that's 20hp guaranteed

    After months of slowly designing ducts and the bloody core boxes, I have got about half of them done and made some cores







    3D printing is really something when making casting core boxes. Almost hard to believe that the core piece turns out looking exactly like the model on computer screen. It's just a very time consuming process to think out how the box is split and creating proper clearance on a core joint etc...

    This time I try epoxy as a core sand binder. Sodium silicate works, but I found that in an iron casting the cores will become almost rock hard and require a masonry drill and an awful lot of scraping to remove. I heard that an epoxy core should pretty much fall out after the epoxy has burnt. Only about 3% of epoxy is required(even less works with perfect core box design) and the core seems stronger than with sodium silicate. I just hope that the epoxy does not release too much gas.

    By the way, always impressed with Flettner's creations! I plan to also cast engine cases some day, you make it look easy..

  15. #4830
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    12th March 2010 - 16:56
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    TT500 F9 Kawasaki EFI
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    Hamilton New Zealand
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    I remember, melted down sewing machines. Good to see some real pattern making / casting going on, good on you.

    I don't have a lot of time these days for foundry work, or for that matter any development work. Too busy, I've landed a nice manufacturing contract ( nothing engine or motorcycle unfortunately) but never the less good enough to keep the parasites off my back or at least give them some thing to feed on.
    Weekends are looking way more precious.

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