- Видео 71
- Просмотров 351 656
Odds and Ends Machining
Добавлен 24 апр 2021
I'm Jonny and this channel is about bringing engineering projects to life and sharing them with you.
Oddsandendsmachining@gmail.com
Oddsandendsmachining@gmail.com
Lost Foam Casting - V4 350cc Engine
In this update I'll show off my lost foam cast V4 2 stroke engines front crank case half. I'll explain some of the process and look at the casting in depth and explain what went wrong.
The foam was machined on my CNC mill using fusion 360 and Mach 3
The foam is extruded polystyrene or XPS
The material is similar to LM25 and was virgin casting stock
the refractory is Gib 4+
The wax is fiberglass mold filleting wax
Subscribe make sure to like the video
The foam was machined on my CNC mill using fusion 360 and Mach 3
The foam is extruded polystyrene or XPS
The material is similar to LM25 and was virgin casting stock
the refractory is Gib 4+
The wax is fiberglass mold filleting wax
Subscribe make sure to like the video
Просмотров: 32 945
Видео
Can I Fix This Broken Band-saw?
Просмотров 8922 месяца назад
Here's a random video of me repairing a BS-7DS band-saw I bought cheap a few months ago to flick for a tidy little profit. These little money makers help fund the V4 project. . . and my Land Rover money pit. It involved removing busted bearings in a creative manner and giving it an overall tidy up. Facebook market place always seems to have deals like this going cheap. Make sure to like the vid...
Lost Foam Casting - V4 2 Stroke
Просмотров 6 тыс.2 месяца назад
In this video I show off my new 'Test' casting which was lost foam cast. I also give a brief run down of the engine design and explain what is next for my V4 2 stroke GP motor build. The next step is to get some more casting supplies together and head to the foundry to have the gearbox cassette plate and the front crankcase half cast. After that I will machine the foam pattern for the rear cran...
Ready to Cast - The V4 2 Stoke Build
Просмотров 8 тыс.4 месяца назад
In this video I'll update you on the progress of the V4 2 Stroke motor build, I'll cover some considerations and the situation when it comes to casting this. This was designed by me in fusion 360 and the patterns were made at home on my CNC mill. I plan to lost foam cast these in aluminium and have them heat treated to T6.
Racing my Home Made V-Twin Engine (Onboard)
Просмотров 1,9 тыс.5 месяцев назад
Here's a video of my most recent Mini GP race on the 144cc V -Twin. In all the bike went pretty well in the race, although it needs some further development. The gearing seems a bit too short and it could do with some higher lift camshafts to raise the max rpm as it falls flat around 9,000. I would also want to add an oil cooler to keep the power consistent over the duration of the race. I'm ge...
Replacing Head Gasket with O-Ring
Просмотров 2 тыс.6 месяцев назад
This week I replace the copper jointing spay head gasket (if you can call it that) with a Viton O-ring and some Hylomar universal blue. I attempt this at first on my CNC mill which ends in failure so I end up machining the O-ring groove on my trusty lathe. I also talk a bit about the V4 2 stroke project in regards to the lost foam pattern. Make sure to subscribe and support the channel Thanks f...
Making a Lost Foam Pattern - V4 2 Stroke Build
Просмотров 1,7 тыс.6 месяцев назад
Just a quick progress update on the V4 2 stroke GP engine, I've made a pattern of the cassette plate for the triumph gearbox and am now looking at getting it lost foam cast. The pattern was made on my CNC converted optimum MH-28V CNC mill. Progress has been a little slow but I am happy with the design and ready to get stuck in (where time permits).
4 Stroke Top End Rebuild
Просмотров 7517 месяцев назад
This weekend I rebuilt a 2013 Kawasaki KX250f, One of the bros had been thrashing it down the beach and it stopped running. Turns out that tight valve had gone soft being titanium and cause the bike to lose all compression. After dropping a large amount of shim thickness on that one valve and still having zero clearance, I realized what had happened and told the owner the valve is toast. The ow...
A 100% Reliable Motor Made in My Shed
Просмотров 2,5 тыс.7 месяцев назад
A 100% Reliable Motor Made in My Shed
Can I Make a Cheaper 2 Stroke V4?
Просмотров 2,9 тыс.9 месяцев назад
Can I Make a Cheaper 2 Stroke V4?
How to Make a Motorcycle the Easy Way
Просмотров 2,8 тыс.10 месяцев назад
How to Make a Motorcycle the Easy Way
Weekly Update - V Twin Exhaust, V4 2 Stroke Build, RGV 372
Просмотров 73710 месяцев назад
Weekly Update - V Twin Exhaust, V4 2 Stroke Build, RGV 372
Machining my Handcrafted V twin engine
Просмотров 2 тыс.11 месяцев назад
Machining my Handcrafted V twin engine
Fabricating a Mini-GP Motorcycle Chassis
Просмотров 2,1 тыс.Год назад
Fabricating a Mini-GP Motorcycle Chassis
Ali express YZ85 Cylinder too Good to be True?
Просмотров 2 тыс.Год назад
Ali express YZ85 Cylinder too Good to be True?
I'm Building a V4 2 Stroke GP Motor [Update]
Просмотров 1,4 тыс.Год назад
I'm Building a V4 2 Stroke GP Motor [Update]
Making a Brake Adapter for the Mini Race Bike
Просмотров 733Год назад
Making a Brake Adapter for the Mini Race Bike
I Made My Own V-Twin Engine - First Start
Просмотров 5 тыс.Год назад
I Made My Own V-Twin Engine - First Start
DIY 144cc V-Twin, A Better Tensioner
Просмотров 1,4 тыс.Год назад
DIY 144cc V-Twin, A Better Tensioner
Machining a Brass Screw (Idle Adjuster)
Просмотров 1,3 тыс.Год назад
Machining a Brass Screw (Idle Adjuster)
Great job there! I was just thinking if you'll be using an aftermarket crankshaft or are you making your own? In my mind, that is the trickiest part...
Thank you. I am modifying the standard crankshafts to work in my cases. Well that’s the plan, i am going to avoid making anything such as crankshafts unless absolutely necessary.
That is some excelent work rigt there! I also had the same ideat but I dont really have money to buy milling machines. Seeing someone doing this is just amazing. Very nice job and good luck with next projects 👍.
Can I ask you how much was the cnc mill or where did you bought it? Whats the name of it?
Thanks you. It’s an Optimum MH28V, it cost $2,800 nzd. The conversion to CNC was about $1,000 or less. It is similar to a grizzly G0704
Awesome project mate! I'm just about to kick off building a V4 too, my plan is to use KTM 125SX parts and fit it into a BMW S1000RR chassis. I'll be watching closely!
Thanks, it’s a small world. I remember running my RGV up on your dyno years ago. Have you started the design yet?
Good job!
I looked up PWK28 carbs, came up with 82mm long.
Also have you looked at the RZV500 Yamaha
I’ve look at everything I could find. This design is loosely based on that.
Have you had a look at that RG500 somewhere in nz with the special V4 upper case half on it? I saw it at one of the Burt Munro rallies that I went to in the paddock at Teretonga. It was a work in progress and had been for some time...
I’ve seen pictures of it. It’s a neat idea, but donor engines are rather pricey. Rather than find a donor RG engine, I’d rather make the entire thing.
Sweet video - I'm looking to start a small foundry/machine shop and seeing a "foam" part "dipped" in plaster seems like a quick and dirty way to make parts - i like it and look forward to seeing your engine run! I'm working on a two stroke, similar to Ferrari's oil sump two stroke design
Thanks. That sounds like a cool project, keep me updated.
Reminds me of the langen v-twin. Its really a shame that not many 2 strokes are made anymore
Well, not many, if any road going 2 strokes. Mx bikes are still being made and selling in large numbers thankfully.
This video made me depressed, this morning my honda CC110 was stolen
This is amazing! Good luck with the project! A 350cc 2 stroke V4 sounds very interesting.
Home made motors! \(^_^)/ EXCELLENT!!! (~_^)-b
What size tires and rims
12” from aliexpress Tyres are pirelli super bike 12” slicks 100/90-12 120/80-12
After rough machining you can rubber mold to reproduce full plaster cast lost wax patterns.
That’s always another option. I think I might try my hand at using resin bonded sand first. Wax could be good for some of the more intricate parts like the water pump cover.
Best I can do is $350
Divide it by 5 . . . Although I didn’t pay for any labour, as I did all of that myself, only the molten material by weight.
Hi. Just find your channel. That is amazing! You do things like me! I have been using just a regular hi temp engine sealant silocone for cylinder head sealing. It works just fine on liquid cooled engines, and as well on air cooled ones. And of course it works just fine as usual engine sealing as it is named. But yeah, you really have a brilliant youtube channel! This is just the way I like it!! Thanks a lot for these nice videos! I appreciate very much!
Thanks, I’m glad you’re enjoying the videos.
It would be interesting to know how much porosity is present.
I guess we will only find out when I begin machining. I’m not going to cut this up and test as I’d rather just crack on with the project. The V twin motor had no major porosity present due to the pour, the only porosity was due to pouring at too high of a temp and having more hydrogen dissolved in the aluminium.
Fantastic work! Love your channel.
Thank you
Why not a v-5
Imagine trying to package 5 exhausts. . . The major problem with multi cylinder and big bore 2 strokes is making good efficient exhausts fit.
Looks better than factory made engine cases from my 50cc jawa 😂
That’s either a compliment or the bar is very low haha.
@@OddsandEndsMachining the cases themselves were good, the machining tolerances and cylinder to liner fitups were a different story. In some cases 5-7kmh difference between Monday and Friday cylinders. Quite a lot on bikes with top speeds that wouldn't get you a ticket in the city. Great job on the castings man!
Mate... starting to come together. Looking bloody good! Sitting on the edge of my seat waiting for the next vid! Congrats on the progress so far.
Thank you, I can’t wait to get the next patterns made, hopefully i get them done in the next couple of months.
Rad bro. First time I've seen your channel. Subbed
70 NZD is a very cheap price, where are you based?
It is, it was a bit of a special deal as I showed them the entire process for the lost foam and explained all of the steps. Also, I took my own sand and all of my own supplies and prepped the mould myself. I’m in Palmerston North.
If someone made a light 500cc v twin two stroke it would sell like hot cakes. Should be around 80hp and 1/3 lighter than a 4 stroke.
Something like that would be cool, maybe like a 2 stroke version of an Aprilia SXV550 motor. I wonder if an MX gearbox would survive.
Since I have no idea about what it costs you. I'm going to just guess that it cost you three kangaroos! Just kidding.
I’m guessing 1 kangaroo is worth more then $25 otherwise 3 kangaroos is close haha. Although in NZ a kiwi might be a more relevant standard of measure.
Kiwi's measure in sheep. Baaaahhh 🤣
Rather than think in terms of milling- glueing up- and then ramming sand molds on all these parts you will burn out, you should look at it from the opposite perspective. That is, think of the MOLD as a group of parts you are trying to mold. That is, mill up patterns that would assemble to make the mold, with keyed inserts to print the cavities and such. Make rigid or silicone molds off those patterns. And that way you just fill those molds with investment, or with bonded sand, to make identical sets of mold parts. That way, you can cast as many engine parts as you want that will be identical, without having to go thru all this tedious hand assembly of foam bits for every part you want to make.
This has crossed my mind. If it works out well and it’s something I want to produce in small batches, this will be the method I use. I have access to resin bonded sand now which would be ideal. The only reason I am using foam for the prototype is for the convenience/cost and quicker pattern design.
Superb Aussie, superb.
I am very surprised for a lost foam casting.👀 You use plaster on your mold,,,, strange. 🤔 The result are great so good job man. 🙋
Thank you, the plaster is just a cheap substitute for the more expensive commercial grade refractories. It does a fairly good job and is fairly inexpensive.
good job i hope more videos
That’s wicked, can I have one?
Thanks, I will see how this one goes and I might sell a few machined castings when it’s up and running.
This is very cool, amazing to watch the process on youtube by a home builder! I was thinking there have been quite a few "V4" twostroke builds in recent times that mimic the Yamaha, Suzuki late 500cc models, No one has made a true V4 design to mimic the Honda 500's. I think there is an opportunity there as the NSR replica's with RG, NS motors would be more awesome with the right motor. I think on Facebook there is an Aussi guy currently working on doing just this, could be an opportunity to collaborate! ;)
Thank you, pass on a link to his page if you can. The main reason for using a twin crank is off the shelf parts which will be available for a long while can be modified to work. An nsr style would require custom cranks which would cost a lot to make and mean you’re making a lot of spare parts to keep the bike running. Using NSR 250 crank parts might be an option, although those parts aren’t cheap and won’t be around for very long.
Very nice. Any idea how many hours you had in at this point? Surprised you don't have more subs as the content here is great..
Thanks, i’m sure the subs will increase, I just need to upload more frequently. The design took far longer than it should have although I was learning how to use fusion 360 as I designed the pattern. Maybe it took about 3 months of occasional modelling on the pc after work. The casting and machining the patterns could have been done over two weekends. Machining the cases doesn’t take that long, maybe a weekend for each half. But being my first time it took a lot longer as I had to fix lots of small design flaws and sort out how to tension the cam chain amongst other small challenges. For reference, I’ve started another engine (not the V4) and the design is close to finished after 3 weeks. I think I’ve developed a bit of a process now.
New sub here. I too am a machinist and motorcycle guy all in one. I've been hoping Allan would do a full video series on how the little V-Twin is made, for quite some time. I would one day like to build one of these..
I reached out to him a few times and had to figure it out on my own. It was probably for the best to be honest. I could sell some castings further down the track if enough people are interested.
Bloody good
Bloody awesome. I had this same idea some years back, make a V4 out of 4 85cc cyls (I was thinking of using KTM cyls and cranks with individual cranks like the factory RG500 GP racers used) Lack of money and tools plus a young family...
Thanks, my engine is also using individual cranks, joined with a coupler. I can definitely relate to having a young family, a new born and 3 year old mean I have to plan my limited garage time a lot better to maximise productivity.
What sort of cylinder head is that?
It’s from an ancient old Toyota Corolla, the water jacket in the head had eroded away into the head gasket sealing area. I had to weld it up and then machine it flat and lap it.
HOLY SHIT THE V4 ENGINE DOES EXIST
Half of it at this stage haha
@@OddsandEndsMachining hey, its more progress than I have on my project, im stuck at the stage where designs are finished but I dont have the funding or following to start actually building it. I have an idea: I'll start designing a small sedan that uses your engine, and once it's done we sell them. It would definitely be a better choice to start with than a mid engine supercar like I've been working on.
@@JaxxonBlaze69 sounds like a plan haha, I doubt this engine would be able to move a car off the line without some serious clutch abuse and horrific fuel consumption.
@@OddsandEndsMachining eh, thats what R&D is for lol
@@OddsandEndsMachining My grandfather had a old Wisconsin v 4. As far as I know it ran but unfortunately I never got to see it run. It was originally made for farm use. So it was never in a car.
Maybe using 4 valve head from Yamaha LC135 or Honda C-series/KPH aftermarket head in the next build? I think that would be cool :D
It has crossed my mind using gy6 cylinders and 4 valve heads for the next version of the motor. . . I might get around to it.
Nice little flip!
Rotor porting vid 😀
There’s a brief video about it on my other channel, I might cover off the intricacies of setting it all up and programming it if I get time.
I want to build something like this Soo bad.. maybe a V8, V10, v12. Designed to fit in the place of a Chevrolet V8. Possibly cast custom cylinders using cr500 pistons. Possibly a big bore version with a stroker crank, adding about 12-15 possibly 20-30 mm to the stroke and 6-12 mm to the bore. Use a supercharger /scavenger with bypass and a reverse centrafugal clutch that disengaged with more rpm, and use a couple turbos would be better for automotive use. Over crankcase breathing. With roughly 600-750, 800 cc per cylinder firing ever TDC, it's going to be a monster. Heck I'd like to build a parallel twin, vtwin, v4, built like a Detroit Diesel, 2-71,2-92 only a gasoline burner, a supercharger scavenged 2 stroke with valves for the exhaust . Using two then later 4-exhaust valves per cylinder!🤯, this has potential to make seriously insane power if the intake can supply enough to make use of it. With the intake ports surrounding the cylinder at. BDC. RPM is not your friend. Maybe a gas version could incorporate a supplemental intake valve in the head to open as the sleeve port is closing a high lift low duration to open while the lower are closing { OR } just use valves for both. A 4 valve design with really high ports so small exhaust valves can flow high CFM. With large long intake ports. Required longer valves. Use a double overhead cam. To allow cam timing and event timing changed to suit scavenging. Direct injection possibly using a high pressure accumulator store about .6 litre at 150 bar +/-50 bar. And port injection for high rpm high power to supplement fuel . E-85 to E-100 would be exelent. Two cylinders with about 1000-1200+cc each. With a bore being 150-160% of the stroke , say 50 mm stroke 80 mm bore.. But on a more reasonable level, my china scooter has basically everything possible done to it. High compression, big bore, big carbon, ported head. Gy6 50 cc with a cam, it's doing about all it can even turning 10k rpm. If like to cast a new case. To allow two 150 big bore cylinders to be used with a stroker crank. Doing about 200 cc each and possibly convert to a motorcycle head with 4 valves maybe two XR250 heads welded together. What would be awesome is cast a case to hold a xr,250 engine allowing the transmission to be used with the scooter rim. Capable of 0-60 in less than 4 sec, 0-100 in 6 sec,with a top speed around ,105-110 mph would be awesome. I doubt over 60-70 would feel safe!
If it’s something you seriously want to do, I would start with something small that uses common affordable parts. This way you can apply what you learn to bigger projects later on. The biggest learning curve is the 3D modelling, but it is also the cheapest step and can be done in any time frame.
Awesome work. cant wait to see how it comes together
Subbed!
Top job.......Thanks for posting...........
Thank you
So cool , good job on the foam came out well! Would lost PLA casting work for something?
Yes, although printing that pattern would have taken a long time to print, it would have also required a special coating for the shell casting.
Wow you are good at fusion 360! And a kiwi as well ? I’m going to have to watch all your videos now and subscribe 👍
Thanks you, Fusion 360 is pretty easy to learn, although I’m probably using it at least 2-3+ hours a week. I am self taught in regards to using CAD and CAM programming. Yep, from NZ living in Palmerston North.
Boy, that little guy is gonna make some *T O R K* 😳
I think it’ll make a lot of noise and maybe a little bit of torque haha.
Excellent are you nz based would love to hear this thing if its ever out and about
Me too
Yes, based in Palmerston North. I’ll make sure to bring it out to Motofest or something similar when it’s done.
@DktheWelder when you gonna start casting some bits make a small foundry behind the shed haha make some cast iorn safty corcs 🤣
@@BIGSMOKE-bl2lq haha don’t get me started I went down a full rabbit hole of get the yz85 cylinder making the crank housing to power a jet surf ! I have so many projects on haha. Should have another video out soon
@@OddsandEndsMachining nobody doing this cool stuff ever seems to live in Hamilton haha
You're the next john britten, what part of nz are you?
Thanks, Palmerston North, it’s not as bad as they say haha.
I can only imagine the huge relief to see it come out as such a successful casting. So much time and effort paid off. I have no idea what the material and foundry cost would be, but I'm very interested to know the tough figure. As for the foam surface finish, I wonder if there is a way of doing a DIY wax spray to act like a high build primer. Over the years Ive been a bit interested in the very cool process of metal spraying. Amazing process for building up worn shafts and expensive dies or machine parts, but also used as an alternative to galvanising or electroplating for corrosion resistance. I wonder how hard it would be to modify a HVLP spray gun with a heated cup and gun body. It may be a case of smoothing the foam surface out with warm tools (which would be a massive time killer), but it could result in a light even texture that could be left as sprayed.
It was a massive relief, it would’ve been demoralising if it failed, probably showing me down a bit. All up it was $70 although, that is a bit of a special deal, but if you showed up with your own patterns you’d be looking around $250-350. The problem with too much wax is it creates more gas and would cool the aluminium down too much, the foam can be sanded very smooth, I was just a bit lazy in this case.