I've Been Busy

I've been staring at these dumb cases for a few months now and recently touched them. It took some time to cut the hole out being as I don't have a mill, so a hand drill and die grinder had to do. Once it was cut out there was a large gap between the intake plate and one case half so I had to mix some JB Weld to let run into the gap. I hate the idea of JB Weld inside an engine, but the bulk of it is underneath the intake plate so I don't really see it letting free. Top plate looks ugly, but it will be sanded and refinished before it gets put together.

The Hodaka is getting there. Just a few loose ends to tie up. Top end and reeds added, pipe built, and most of the electrical has been finished up. I replaced all the spokes front and back, so the wheels need a little more truing up before I can mount tires on it. I don't have a photo since it's in a storage unit. ughhh

Also I moved out of town and lost my garage. My life is in a storage unit right now. UGHHHH

Puch Sabre Winter Madness!!!!

Took the engine off my Sabre the other night. I have an Airsal 47.6 cylinder thats been sitting in a box since I bought it in April. The cylinder is designed for stroked out minarellis, so the stroke of the cylinder is 43mm. Hey, that's what e50s and sabres use! Convienent, right? Yes. Only downside is the Sabres case is 3mm too tall so that will need to be dropped. All of the engine parts have been pulled out and the cases have been soaked in some degreaser from the dollar store. I made a video of pulling the transmission apart that I'll post just as a guide for anyone rebuilding a Sabre engine and needs to know how or where something goes. So now my plan is to have 16mm milled off the deck, two 1/2" plates welded in so there's extra meat for the huge transfers, and new cylinder studs added. Then two plates will have to be added to the top to convert it from piston port to case induction. Then it'll most likely get a DIO manifold added since they're pretty cheep and easy to put on anything.

I don't update this a lot and I'm done with mopeds.

Yup, mopeds are kinda a waste of time I've realized since starting to dabble in shifters and bigger bike. Still have my heart in two strokes though. Got a few new bikes since I've logged on here last. Ones a Hodaka Ace 90 in super rough shape, there will be more on that as time goes on. The engine has been rebuilt, but the rest of the bike will need work before it goes back on. The other is a clean Honda CB350 that just needs a little tinkering and basic maintenance. Also, I've taken the engine off my Puch Sabre to do some crazy stuff with, but that'll get it's own big ranty post. Heres some pictures I guess. So you know, ATF and gas burning on a seized piston doesn't free anything worth a shit. I read that's how Chevy guys do it. Haha! The grey stuff on the top right of the Hodaka tank is Alvin's Lab Metal, a gas resistant body filler. It sucks ass and doesnt work well. if you were wondering.

This happened.

Been a while since I've posted last. Here's where the case inducted e50 sits. Cylinder intake delete plate made. Case halves gooped up and put together with stainless Allen heads. Hpi installed. Treats race crank with new seals and bearings. I cut new gaskets for the reed block since the og ones were shit. Bottom end all assembled and ready for the top end. Still undecided if I want to ad a locator pin to bottom of the case and cylinder to keep things aligned. Currently I have small cut pieces of knitting needles in the cylinder (Walmart purple needles (6mm id! Whahhhh)) but the studs I'm using aren't a true 6mm on the unthreaded section and there is still a tiny bit of wiggle when it's on the studs. Most people and factorys put cylinders on and skip this part but I'm pretty attentive to this kinda thing. We'll see when it comes to it soon here.

Case welding.

Welding aluminium sucks. Puch cases are the thinnest around the crank on top. Thinner than everywhere else at least. I had to do hot tacks around the hole I cut and die grind them flat just to get it built up. Air leaks are my enemy here but that was the best I could do. Straight beads would have just caved in and running my machine at a heat setting low enough not to cave in wouldn't penetrate the metal. After getting it built up I was able to do a few beads with the hot setting. Then die grind it flat and later hit it with a small sanding disk on my drill press. I don't have access to fancy tools... Now I'm ready to weld my plate on from the inside. Not really worried about making the port smaller as it will still flow a huge carb. A vm24 is what I have now from an old Yamaha dt175. I'm pretty nervous, but it's 1/2" thick so at least I won't burn through. I'll seal the deal with epoxy when it's all said and done. I got the transfers welded up too so I can cut massive ports later. 

Cases.

I got a set of cheep e50 cases for the maxi. The lip around the flywheel cover was ground off and they were all crusty and white with some weird crap corroded on them. I gave them a quick sandblasting to take it off and cleaned up  around where the lip used to be since it was uneven. Then drilled and tapped a new hole for the hpi. Not sure if I even needed to, but ohh well. Better to have it and not need it then to need it and not have it I guess. I will weld them up for larger transfers probably this weekend. 

Also started cutting the hole out of the plate for the case induction action. It's not all the way done of course. 

Maxi time.

So I had big plans for this guy earlier this spring. Ordered a Parmakit 47.6 LC kit for Minarellis stroked to 43mm. That was at the beginning of June. Over 3.5 months later, nothing and I'm out $260... Hopefully PayPal comes through and I get refunded. Anyways, I pulled it out today, put new IRC 2.0" tires on the rims and cleaned it up a bit. Also the radiator mounts I welded under the tank were cut off. :( I'm still going to do the case induction with a DIO reed block though. It'll probably get the cases welded up, stuffy crank and a Hero kit + other junk.