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  #1  
Old 27-06-2011, 03:57 PM
MisterB MisterB is offline
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Default My projects

Keeps me busy...

First the Compbike, pretty much all home made in a shed, took three years so far and still not finished.

Next a simple rigid chop, with 127 El Bruto motor, 6 speed box, and decent brakes, taken from a Ducati 998. Its going to have a one off exhaust, oil tank forwards etc, not sure of the details yet, but its looking ok so far.

Last, my Merch 131 spent a lot of time on my mates new dyno over the winter. We filmed one of the early dyno runs on an iphone, aint too great, even with baffles, its too much for the mic. Its here on You tube

http://youtu.be/gJq4fZk--jI

It was clear the V&H exhaust would have to go, so now making a new system in stainless with one off conical megas, hope to have it all done by next week.
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Old 27-06-2011, 04:00 PM
W.I.T.C.H W.I.T.C.H is offline
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coolies
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Old 27-06-2011, 05:18 PM
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Default Forgot to mention

The pipes are being made by Saf at Not A Fridge. I got a new camera the other week, which can take moving piccies, so here's a quick tour of Saf's workshop, as I wander about trying out me new fancy camera... lots of weird stuff being built... I like the little white ducati cafe racer, in for new pipes and Turbo Yam GTS...

The black Harley Bobber at the start had been ridden in for some tidying up, someone beforehand had got the oil lines mixed up, its surprising how far a Harley will go without any oil in the motor ...

http://youtu.be/gwzmi75QUvU
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Old 27-06-2011, 05:36 PM
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Default Couple more pics

Racing at Santa Pod on my Merch 120 (+NOS).. just doing a burn out during qualifying, and waiting for the light... won that one
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Last edited by MisterB; 08-04-2014 at 12:36 PM.
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Old 27-06-2011, 05:48 PM
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Looking good!
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Old 27-06-2011, 06:57 PM
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Excellent.
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Old 27-06-2011, 07:42 PM
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my hat goes off to you sir, any guesstimates of times/hp for the comp bike?
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Old 27-06-2011, 08:06 PM
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my hat goes off to you sir, any guesstimates of times/hp for the comp bike?
It depends how much Nitro we want to run, it'll probably blow up on the line, but guesstimates are about 800 bhp and mid 7's...
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Old 27-06-2011, 08:12 PM
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wow cant imagine the feeling of sittin on summat like that and launchin off the line, im sure its pretty mental tho!
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Old 27-06-2011, 09:14 PM
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wow cant imagine the feeling of sittin on summat like that and launchin off the line, im sure its pretty mental tho!
Thats' why you have to wear a sort of flak jacket if you ride a nitro bike these days. If it ever gets finished, I'll let you know how it feels to launch it.
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Old 29-06-2011, 01:42 AM
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Default Making a stainless exhaust system..

We had to pull the baffles out of the V&H exhaust to get more power when my 131 was on the dyno. Thats ok, except its now ridiculously loud and doesnt run too well at low rpm, despite the fueling being spot on. Effectively I'm running drag pipes with a very big cam, so its no wonder it pops and spits back at low speeds.

So time for a new exhaust system, I never liked the V&H system anyway. The new one would be made from 2 inch stainless, be a 2 into 2, with conical megas, machined headers and with billet end caps, oh and minimal baffling.

I used paint on my PC to roughly draw out how it might look...
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Old 29-06-2011, 01:50 AM
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Default Making a new exhaust system part 2

Originally I was going to have a 2-1 system, as this gives better results normally, but I hit a problem finding a suitable 'cone' of the right size,so went for a 2-2 instead. The motor is making 140 lb/ft of torque at the mo, so its not as if it needs anymore.

So first step get hold of a stainless cone, perforated tubing and a nice piece of billet...

Next machine a billet end cap, so it fits just right and also holds the perf tubing nice and snug.

Finish off by making a second cap and drilling them to take a bit of weight off and add a bit of style.
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Old 29-06-2011, 01:59 AM
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Default Making a new Exhaust system part 3

Next step was to get hold of a enough 2 inch stainless bends, both 45 and 90degree, hope not to use too many as they aint cheap..

Then, to be different and to ensure max flow at the heads, we machined a couple of 'headers' in stainless which wont need any gaskets, they will be held in place by the std Harley clamps.The downtubes will then slide over these headers and be held in place by some yoshi exhaust springs, also stainless.
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Old 29-06-2011, 02:07 AM
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Now its time for the tedius bit, carefully cutting the stainless bends and straight tubing to make the downpipes. Sounds easy, but it isnt, it takes a lot of time and effort to get it right. BTW the downpipes are going to be approx 30 inch in length. With a big twin Evo, typically the range of downpipes length is between 25 and 40 inchs. The longer the downpipe (all things being equal) Peak torque appears lower down the rev range. I want peak torque to be at quite a high at about 4,500 rpm, hence the fairly shrt headers. My drag bike has a 120 inch motor and 25 inch headers, which gives max torque at 5,200 rpm, too high for a road bike but ok for a race bike.
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Old 29-06-2011, 02:23 AM
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The narrow ends of the cones are only 1 1/2 inches in diameter, so the plan was to cut the down till the narrow end was 2 inches in diameter, then we'd have to weld on a short stubby 2 inch tube (actually it would need to be swaged to make it slightly wider), so that the cones could then slide over the downpipes. Thats a lot of faffing about, so instead we used this neat machine to do the job for us...

check it out here http://youtu.be/YajRKzutrc4
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Old 29-06-2011, 02:12 PM
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Quote:
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BTW that bike is now on the road
ridden by the nutter Saf by any chance?
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Old 29-06-2011, 04:07 PM
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How did you guess Yes its a bit different now, not quite finished yet but its otr.. I got to keep all the drag race stuff, air shifter, rear sets, exhaust system etc, so intend to build another big inch Evo racebike someday.
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Last edited by MisterB; 18-04-2014 at 11:56 PM.
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  #18  
Old 29-06-2011, 04:48 PM
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Default Building the compbike

Well, this project has been ongoing for more than 3 years and its still not finished, though not from a lack of effort. Building a one off engine takes a bit of time...

We started off with a few billets of aerospace quality alloy and an ancient milling machine, and after many hours of careful work, we ended up with a pair of crankcases and a block. There is no cnc stuff here, its all done by hand, one mistake and the cases would have been scrap.
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Old 29-06-2011, 04:52 PM
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We used this crude looking cutter to scoop out the cases, as with jusdt one cutting tooth, we found it easier to control.. BTW when I say we, I should mention that my mate Jeff does all the hard work, I just drink tea and scoff his fav biscuits..
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Last edited by MisterB; 29-06-2011 at 05:13 PM.
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Old 29-06-2011, 04:56 PM
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We didnt just make the motor, we try to make everything from whatever we can get hold off cheaply..

That includes making the wheels, the front uses rims recycled from a damaged Astralite, while the rear uses rims from a composite car wheel, a compomotive I think. Jeff even made a matching set of discs too.
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Old 29-06-2011, 05:08 PM
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The engine is a bit like a Harley evo in that its pre unit, with a homemade belt primary attached to a 2 speed B&J gearbox. The clutch is home made too, using clutch plates from a Ford Escort Mk1 rally car of all things. Ignition is by two magnetos (they sit behind the block, with the blue end caps), so that if one fails the other will still work, a failed ignition can result in instant hydraulic lock as the cylinders fill with Nitro, then its bye bye motor, something we want to avoid. The head is loosely based on an old Zed, but reversed with a supercharger at the front, and with an extenal hi pressure oil pump. The crank runs shell bearings, this time taken from a Hillman Imp, as they are the correct size.
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Old 29-06-2011, 05:10 PM
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And finally, here is another project my mate has been working on for more than a decade, a top fuel motor... all made in a shed.
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Old 29-06-2011, 05:12 PM
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He's a bit of a smart arse is Jeff. A damn good engineer too
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Old 01-07-2011, 06:59 PM
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He's a bit of a smart arse is Jeff. A damn good engineer too
Yes he is a good engineer and machinist, I just wish sometimes he'd work a bit quicker lol
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Old 03-07-2011, 10:36 PM
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Originally Posted by MisterB View Post
The narrow ends of the cones are only 1 1/2 inches in diameter, so the plan was to cut the down till the narrow end was 2 inches in diameter, then we'd have to weld on a short stubby 2 inch tube (actually it would need to be swaged to make it slightly wider), so that the cones could then slide over the downpipes. Thats a lot of faffing about, so instead we used this neat machine to do the job for us...

check it out here http://youtu.be/YajRKzutrc4
Not much progress this week, my mate Saf has been working 12 hour days 7 days a week, so I cant really ask him to work on my freebie at the mo. Instead, last week I paid a visit to Cam Coat in Warrington http://www.camcoat.com/main/site/ , not far from me, and had a good chat to the owner. The prices on their website or well out of date, but he worked out the price to ceramic coat my exhaust which came to about 130 plus Vat, thats for the slightly more expensive cermakrome finish, which looks like polished alloy to me rather than chrome. Their turnaround is between two to three weeks, which is no good to me as I want the bike back on the road next week. Instead I'm going to polish the stainless system and wait till the winter to get it ceramically coated.
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  #26  
Old 06-07-2011, 06:01 PM
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Default Made some good progress this afternoon..

Perf tube 'baffles' fitted into the cones, header springs on and downpipes tacked together. Still lots to do, but hope to have it all done by the weekend. Big thanks to Ash and Saf at Not a Fridge for their help today
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Old 06-07-2011, 08:08 PM
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Jesus man , that shed made motor is a monster. I've raced some wacky shit but this is the nuts , I dought i could handle putting that down on the tarmac on four wheels let alone two. Realy gets the juices going , keep us posted man you've got me riveted.
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Old 08-07-2011, 10:46 AM
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Time for the boring work... linishing all the welds, then they'll need polishing, not looking forward to doing that..
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Old 18-07-2011, 02:04 PM
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Finally got the exhaust done on Friday, rode it home felt a lot better at slow speeds than before and nothing fell off, so will count that as a success. The next day, I helped out at my mates stand at the Rainy Daze rally, with the bike on the stand, it was fun riding on the wet grass Since then its been raining non stop, so hopefully will get it back on the dyno soon. If it works ok and nothing breaks .. I had a hand in making it, so fingers crossed.. I'll spend some more time polishing out all the grinding marks I left in it and maybe get it ceramically coated.. not sure yet.
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Old 19-07-2011, 02:28 PM
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Rode it home from the workshop today, we checked the a/f ratio which was ok, but no time this week to put it on the dyno.. sounds quite nice though While the exhaust was being made I got the seat recovered, excelent quality but its not quite right so will get it redone over the winter
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