ESE's works engine tuner

[Hemi Makutu]

I'd love to discover a material that is closed to gases and open to liquids. Might get me a Nobel price, so I could fly to Stockholm, all expenses paid, and meet Bob Dylan...

Sorry Frits, but NACA already did it about 60 years ago.. the gas stream 'sees' the matrix as a 'semi solid'.


https://ntrs.nasa.gov/archive/nasa/c...9930084436.pdf

[41juergen]

That's how I try it. For the caps I used the same material as the piston pin and than got it laser welded from a local company, costs were 35,-€ for 2 piston pins. Hope it will work and last...

[Frits Overmars]

That's how I try it. For the caps I used the same material as the piston pin and than got it laser welded from a local company, costs were 35,-€ for 2 piston pins. Hope it will work and last...

I like that timing edge on the piston .

[bjorn.clauw.1]

Most of the research went into finding the proper plug material. And since I don't expect I'll ever get rich from selling plugs, I'll let the cat out of the bag:
the plugs are made of Torlon. The stuff ain't cheap, but you'll get about 20 re-usable(!) plugs for the price of one Pankl pin.

Attachment 326134 Attachment 326135

Does this mean you can provide these plugs?

[Flettner]

If someone wanted to provide the material I have a CNC that says it could make a few. A detailed drawing might be nice too.

[wobbly]

Flettner, I have two pieces of Torlon on the way for 16mm pins.
I will be away for a week in Vegas, they should be here about the time I get back.

[Hemi Makutu]

Would the weight penalty preclude trying them in the piston to support the pin?

Or alternatively, blind-end/one piece-capped sintered bronze bushes inserted likewise?

[adegnes]

Put me on the list for 12mm caps!


https://youtu.be/C9X2eOzACmk



Feel I need to make something with high precision from good plans next, to redeem my reputation.

[41juergen]

I like that timing edge on the piston .

Hey Frits, well spotted (of course you do ). Will get back the barrels next week, modified to take the CNC machined head following the radius at the edge. Fortunately the stock TZR250 3XV barrels have very low timings, so perfect to get the right timing without using too much epoxy....

[Haufen]

That may not break the pocelain but it can very well cause an different problem. An open ended wrench bears on just two points of the hexagon and as the spark plug body is relatively thin-walled, you'll risk pushing the hexagon out of round, causing leakage at the top seal between the hexagon and the porcelain.

Thanks, I will keep that in mind. Although a quick inspection of the broken plugs revealed that all of them were fine in the transition area between the hexagon and the porcelain.
I will now carefully mount the new plug with the proper tooling and report back when I have new findings.

Hey Frits, well spotted (of course you do ). Will get back the barrels next week, modified to take the CNC machined head following the radius at the edge. Fortunately the stock TZR250 3XV barrels have very low timings, so perfect to get the right timing without using too much epoxy....

Nice modification, how did you carry it out? And did you already test the mod? Did you have to relocate the barrel due to the longer effective port timings to get the same shape of the power curve as before?

[41juergen]

Ok, after 2 years reading, asking and learning may be I should be brave enough to show what I'm working on.

The bike is a TZR250R type 3XV which was sold in Japan only. There were 2 different versions available (as the RGV's and the NSR's): the standard road bike and the SP versions (with dry clutch, different gearing and better suspensions). I own the R standard version which had only 45HP based on the Japanese power limitations based on their regulations. That engine has very low port timings (ex port only 184°CA and transfers about 118°CA).
So I took Frits proposal of the radiused timing edge followed by Wob's recommendation of the 7° taper and the flat dome for the piston. The heads got inserts based on that geometry and the 6mm distance from piston to plug tip. I used EngMod to define the transfer port and exduct dimensions, all based on a road going bike setup (the second engine will be the track one). The max power will be around 11.000 rpm, the track engine approx. 12.500 rpm.
As I wanted to stick with the stock pipe (because of the German police ) I only modified the inlet of the pipe based on the 75% exduct area rule (the other engine will get a serious oval to round transition incl. the better pipe). I also followed Wob's idea how to setup the reeds incl. different strength of the upper and lower carbon membrane plates (as the engine geometry required a downstream design to fit the carbs).Further I modified the cooling circuit with the larger curved rad from the TZ with larger hose / pipe diameters and wait for a higher pump impeller. The engine is not complete yet, so I need to see if the result will be close to the EngMod prediction...

[adegnes]

Ok, after 2 years reading, asking and learning may be I should be brave enough to show what I'm working on.

The bike is a TZR250R type 3XV which was sold in Japan only. There were 2 different versions available (as the RGV's and the NSR's): the standard road bike and the SP versions (with dry clutch, different gearing and better suspensions). I own the R standard version which had only 45HP based on the Japanese power limitations based on their regulations. That engine has very low port timings (ex port only 184°CA and transfers about 118°CA).
So I took Frits proposal of the radiused timing edge followed by Wob's recommendation of the 7° taper and the flat dome for the piston. The heads got inserts based on that geometry and the 6mm distance from piston to plug tip. I used EngMod to define the transfer port and exduct dimensions, all based on a road going bike setup (the second engine will be the track one). The max power will be around 11.000 rpm, the track engine approx. 12.500 rpm.
As I wanted to stick with the stock pipe (because of the German police ) I only modified the inlet of the pipe based on the 75% exduct area rule (the other engine will get a serious oval to round transition incl. the better pipe). I also followed Wob's idea how to setup the reeds incl. different strength of the upper and lower carbon membrane plates (as the engine geometry required a downstream design to fit the carbs).Further I modified the cooling circuit with the larger curved rad from the TZ with larger hose / pipe diameters and wait for a higher pump impeller. The engine is not complete yet, so I need to see if the result will be close to the EngMod prediction...

Great stuff! Looking forward to seeing how it goes!
Is that the stock reedbox? Did you modify it?(other than changing reeds) Could be usefull in other applications with how it's angled!

[koenich]

Feel I need to make something with high precision from good plans next, to redeem my reputation.

this my truing tool. 2 lasered vertical plates and 2 lasered v's:



was only few bucks to get the stuff lasered and can be upgraded with small bearings + discs to balance cranks.

[adegnes]

this my truing tool. 2 lasered vertical plates and 2 lasered v's:



was only few bucks to get the stuff lasered and can be upgraded with small bearings + discs to balance cranks.

Wows! Sexy!
I think I need to plagiarize that, just do it by hand - You know, the thing about my reputation...

[TZ350]

this my truing tool. 2 lasered vertical plates and 2 lasered v's:

Wows! Sexy!
I think I need to plagiarize that, just do it by hand - You know, the thing about my reputation...

I had a rough hand cut one, they work just as well, but don't look so pretty. I sure like Koenich's laser cut version, very impressed.

Ok, after 2 years reading, asking and learning may be I should be brave enough to show what I'm working on. The bike is a TZR250R type 3XV which was sold in Japan only.

I love it, please post more and pictures too as the project progresses.