ESE's works engine tuner

[Gradella23]

hello everyone,
just received this beauty: 3d printed exhaust flange with transition from 75% area cylinder duct exit to 100% round area, with aux ducts gradually merging, thanks to @wobbly knowledge

it's 20mm long (40mm bore so 60mm duct+20 flange). I hope to ramp up cnc machining operations on the cylinder and crankshaft soon (not my machines unfortunately) and see if we can get this wobblyduct to go!

[wobbly]

What is the manifold being used on , im interested in the project ?

[Gradella23]

What is the manifold being used on , im interested in the project ?

hello wob, will be used on my 50cc self designed cylinder on an old Cagiva 50 engine.
still work in progress cause we lack time on the cnc machining end of the project... my partner in crime is spending all his f.cking days building his new house. I hope he's finally done with laying the damn parquet later this month

[diesel pig]

hello wob, will be used on my 50cc self designed cylinder on an old Cagiva 50 engine.
still work in progress cause we lack time on the cnc machining end of the project... my partner in crime is spending all his f.cking days building his new house. I hope he's finally done with laying the damn parquet later this month

Very Nice. I like three exhaust ports over bridged exhaust ports and just not because Aprilia did on there High HP RSA125 but because big exhaust bridges have all ways given me problems.

[lohring]

Is that a 3D printed cylinder?

Lohring Miller

[Gradella23]

hello guys, little update, almost ready to melt some aluminium....

Is that a 3D printed cylinder?

Lohring Miller

hello lohring, no it's a casted cylinder, i quote here my previous post where you can see the sand cores: the inner core is 3d printed directly in sand, while the outer core box was self built by me using 3d printed plastic models.

[wobbly]

Gradella , when you said 40mm bore I thought you were referring to the spigot - not the cylinder bore as it obviously is.
I have done a TZ50 where the spigot exit was 26mm = 100% of the port effective , and that was the same as the venturi size of the 30mm HV Lectron carb
it was fitted with.

[husaberg]

hello lohring, no it's a casted cylinder, i quote here my previous post where you can see the sand cores: the inner core is 3d printed directly in sand, while the outer core box was self built by me using 3d printed plastic models.

Sewing machine?

[yatasaki]

I will be there and make some photos. Bump me up we'll have a chat, can't miss me, guy in a wheelchair with camera. I will be with my friend Cerar, he is driving freetech.
20+ riders will participate. I think it is a record. And it's 10th aniversary this year.
Will you race?

I did,😎
We met😉

[Gradella23]

Gradella , when you said 40mm bore I thought you were referring to the spigot - not the cylinder bore as it obviously is.
I have done a TZ50 where the spigot exit was 26mm = 100% of the port effective , and that was the same as the venturi size of the 30mm HV Lectron carb
it was fitted with.

sorry, maybe I wasn't clear. Anyway i got a 29mm spigot exit = 660mm2 of exhaust port total area.

[Gradella23]

Sewing machine?

if you mean FDM print, yes, the external core box models are 3 printed in ABS, coated with a filling primer and sanded to the desired roughness.

[Rudex]

hello,

Wobbly, Why the kz R1 take little channel for water and kz10 take bigger channel?. Im no seeing any hole under the channel?.
Regards

[Vortex]

Hi Rudex,
This small milled groove is only for the air to escape that cooling chamber.

[wobbly]

The factory deleted the water entry up under the Exhaust duct completely with the R1 , as this means the duct heats all the cold water before it runs over the transfer tops.
The 10B and 10C they added a side water hose to push cold water over the duct top only.
The best solution is to use an extended spigot over the top of the duct with holes pointing back over the transfers , and have 2 x3mm holes up from the case to keep some flow
travelling up to the head.
Thr R2 has my spigot extension within the casting , it just needs the 3mm holes to move water around the duct from the case.
This can also be done to a Vortex , as it has a threaded hole in the cylinder - the CIK have confirmed to me in writing this is legal.

[jato]

Re auxillary exhaust ports; i am assisting a small amount with building a set of kawasaki triple cylinders - modern port layout with reedvalves fitted but still non powervalve. at this stage the aux exhaust ducts need to do a gentle loop around the outside of the forward cylinder studs - would this be a no go? the alternative is to relocate the studs but this is not the most preferred solution. any thoughts?