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Old 09-13-2013, 09:43 PM   #16
Doctor
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Quote:
Originally Posted by Fogo72 View Post
The KLX has not got a single backbone frame so it wont fit.

Hey guys, I need to send a base gasket to somewhere that can scan it and cut some new ones out in a water jet, out of different thickness stainless sheet. like 1mm , 1.5mm and 2mm. Anyone know somewhere that has a water jet that could do that?
once upon a time i knew a fellow that did just what you want to do
he cut a one piece alloy base gasket, it worked a treat and he did it by hand tools.
it was a Kwaka 500 triple
so alloy works well
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Old 09-13-2013, 11:34 PM   #17
Eric66
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Who is doing ya crank Fogo? Ronnie?
Regards Eric
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Old 09-13-2013, 11:56 PM   #18
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Who is doing ya crank Fogo? Ronnie?
Regards Eric
Well I have been looking for quite a while for someone to take it on, far and wide, when someone recomended a guy that lives on a farm about 20 klms away from me. I drive out there and was warned, what ever you do, dont swear, they are churchies.

Righto, I drive up the driveway to an old farm shed and an old guy shuffles out to meet me. I tell him of my intensions and hand him the crank, he laughs and said, "just go and buy yourself a CRF450" I said Nah I'm too loyal to these old pigs,
"yeah I can do it no problems but how much money ya got young fella" he said. Well I'm on a bit of a budget for this I told him.
"Leave it with me, $500 bucks"
I follow him into this dingey shed to see wall to wall Mills and lathes, some old ,some the latest technogy. One lathe you could have swung a tug boat prop in, the chuck was so big.
So as I got into the shed he stops in his tracks and swings head around on his shoulders to eyeball me in a weird and hazey glance and I see this little spakle in the corner of his eye as he said, " years ago I used to be right into this crazy sort of stuff with engines" as he chuckles.
He puts the crank on a work bench as he slides a pile of shit to the side and looks at me and says, Thats a guy who is into chain saw racing and I have to make a cylinder head for him from scratch. Ha.

I have a new found friend.

Cheers Fogo..
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Old 09-14-2013, 12:03 AM   #19
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He puts the crank on a work bench as he slides a pile of shit to the side and looks at me and says, Thats a guy who is into chain saw racing and I have to make a cylinder head for him from scratch. Ha.
i have friends up that way that use such modified things , Ask him does he know a Neil or a Bill
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Old 09-14-2013, 12:09 AM   #20
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raised the barrels just on 2mm to optimise the port timing

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Old 09-14-2013, 12:12 AM   #21
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can you mock it up in the cases before you get too far ? often clearance around the rod is tight standard. might need case mods to make it work. also, with altering the height of the barrel you will need to consider how to get the valve timing right and the chain tensioned.

looks like a fantastic project.
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Old 09-14-2013, 12:24 AM   #22
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Originally Posted by wiggywildwildwest View Post
can you mock it up in the cases before you get too far ? often clearance around the rod is tight standard. might need case mods to make it work. also, with altering the height of the barrel you will need to consider how to get the valve timing right and the chain tensioned.

looks like a fantastic project.
Sure, the timing will be sorted with the same mod I did to Kermits new engine, elongate the cam gear bolt holes, the barrel will go up 2mm and the piston shaved 1mm, heaps of adjustment on the cam chain adjuster.
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Old 09-14-2013, 12:28 AM   #23
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Old 09-14-2013, 12:29 AM   #24
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Hey Fogo love your work...

You gunna be around next Saturday or Sunday, I'll be down your way was gunna call in say G'day
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Old 09-14-2013, 12:46 AM   #25
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Hey Fogo love your work...

You gunna be around next Saturday or Sunday, I'll be down your way was gunna call in say G'day

Yeah , still got this helmet here to ay.
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Old 09-14-2013, 01:20 AM   #26
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aarrhh fogo, that's awesome.
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Old 09-14-2013, 01:23 AM   #27
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Originally Posted by Fogo72 View Post
I think we would have to be really carefull trying to take weight off the crank and balance weight, get it wrong and it vibrate to bits. Engine blue printers would be the people to see, maybe the guys who do all the Go cart race engines. But no endless budget here.
We are going for the raised barrel idea instead of getting a shorter conrod made from Corrillo. I might get a base gasket cut out of stainless by a water jet and raise the barrel 2 mm and mill 1mm off the top of the piston to get a round the stroke difference, that way the crank angle wont change too much I have been told, and it decreases the side load on the trust sides of the liner.
Move the piston pin up the piston ? instead of milling the crown of the piston.

What's the length of the stock rod ?

What is the diameter of the piston pin ?

What is the stock stroke ?
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Old 09-14-2013, 01:56 AM   #28
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Originally Posted by KASUYAHO View Post
Move the piston pin up the piston ? instead of milling the crown of the piston.

What's the length of the stock rod ?

What is the diameter of the piston pin ?

What is the stock stroke ?
STD bore is 100mm
STD stroke is 83mm
New stroke is or will be 89mm
1mm off pistom crown , no biggy, kind of domes in so it will just be a little around the out side.
Piston pin, not sure, have book. will find out.
Same with rod length, can find out,
why , whats your thoughts.
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Old 09-14-2013, 02:22 AM   #29
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Old 09-14-2013, 03:48 AM   #30
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Not willing to show you the fairing that we have picked yet or where we are getting from until the deal is done, I don't think the manufacturer would like to see it on KLX, but If I can pull it off it will look sweet. Nothing like a KTM fairing with a huge Kawasaki sticker up the side of it.

A few pics of cam timing adjustment.




Fogo72 screwed with this post 09-14-2013 at 03:57 AM
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