New project - winter model

[coaster]

It isn't the dead weight that matters, it's the reduction in the rotating mass that matters and the 50grams will have more effect that you might think

[dickie]

I did a rough 'back of an envelope' calculation and I reckon I've reduced the inertia by around 10%. Definitely worth it if you're going sprinting or building a peaky motor like an ss225 or rb but I'm not sure it's so significant on this set up. Still, every little helps.

[dscscotty]

Every little bit does help, a little bit here a little tweak there all adds to the final result.

[Warkton Tornado No.1]

I should have made some templates for the edges but I did them by eye. Unfortunately they're (unsurprisingly) not as good as the centre but it's of no real consequence.

You are spot on to be un-concerned for now. I applaud the idea of using CAD to make a template & wondered why you went ‘freehand’ on the sides.

However, if not now, perhaps @ a later date, you can do more work on the sprocket.

You can print on self adhesive transparent then apply as ‘stickers’ to an oil-free surface to get consistent results. For instance, those sides could be modified to oval or kidney shaped slots. Loads of you on here like your ‘Dremels’ but one of my favourite non-bedroom tools is my Makita die grinder. Less than a kilogram in weight, 25 000rpm & you can use proper sanding drums that make porting so much easier.

[dickie]

If anyone wants a pdf or dwg copy of the template, pm me. It has the edge templates on now too

[dickie]

Little bit more progress.

Elemec flywheel, but I've drilled out the rivets and replaced then with 10.9 button heads (M6 x 16 are the perfect length).

DSC_0562_zpsthz6qus5 by richardhenderson1968, on Flickr
DSC_0563_zps1t7v8jsu (1) by richardhenderson1968, on Flickr


Top tip: cover all the magnets in masking tape otherwise it's a nightmare getting all the swarf and filings off them.


That was nice and easy but I now have a problem. The kickstart spring is digging into the casing and I don't understand why. It was obviously doing this in its former life as the witness marks on the casing show.

Any ideas?
DSC_0569_zpsyizxem4c by richardhenderson1968, on Flickr

[jonno]

In wrong way round?

[dickie]

In wrong way round?

Not according to sticky's. It did cross my mind to flip it over but the I think the tangs are different lengths.

[dickie]

OK, I've tried putting the spring in upside down and it's worse. This is a Spanish series 3 li side case with an Italian s3 li Kickstart shafts. I have no idea how to sort this other than buying different springs from different sources. I have 2 scootopia ones and they're both the same.

Someone must have seen this before?

[jonno]

Always a bit of a mark on the ones Ive done,but not that bad.Perhaps try an SIL from Scooter Restorations ,they may have Spanish ones .

[ToBoldlyGo]

There was something about this quite recently. They had the exact same problem with the kick start spring. I think it probably was on here. So worth searching. From what I can remember the tang on the spring was too long preventing it seating properly. Unless I imagined it all, which is possible.

[Toddy]

There was something about this quite recently. They had the exact same problem with the kick start spring. I think it probably was on here. So worth searching. From what I can remember the tang on the spring was too long preventing it seating properly. Unless I imagined it all, which is possible.

Here you go

viewtopic.php?f=10&t=6083&p=50842&hilit=Kickstart+spring#p50842

[ToBoldlyGo]

That's the one Toddy. I was sort of right.

[dickie]

Thanks gents. I've sort of fixed it by using a different spring from eBay, the one on the left. The one on the right is the scootopia one.
DSC_0574_zps9v9qlxcb (1) by richardhenderson1968, on Flickr

It isn't pretty though
DSC_0575_zpshe2y9hiw (1) by richardhenderson1968, on Flickr

By coincidence I had the sidecasing off my series 3 tonight as well. Much nicer and it makes me question if sticky's is correct. This one has its original spring with an Indian kickstart shaft of unknown origin.
DSC_0573_zpss4r2cqsg by richardhenderson1968, on Flickr

[dickie]

And so endeth the slowest engine build in history. Good job it's only got one cylinder!
DSC_0785_zpsut70snix by richardhenderson1968, on Flickr
I've got a couple of weeks off work after a manic 6 months so I'll get the chassis and bodywork stripped and off to Shaun Burns for some beating, blasting, welding and painting.

[xenia1]

Looks a very good job there Dickie, more so considering the state of the original internals

[Topgearskin]

And so endeth the slowest engine build in history. Good job it's only got one cylinder!



I've got a couple of weeks off work after a manic 6 months so I'll get the chassis and bodywork stripped and off to Shaun Burns for some beating, blasting, welding and painting.

Any update on this one? Also when you swapped the rivets for cap heads on the flywheel, what did you use to secure them? Nylocks or std nuts, lockwashers and threadlock?

[dickie]

It's still trundling along but it's been neglected a bit over the winter as I've been busy with my series 3 and work. However I started getting back into it this weekend.

The bodywork was due to go for welding and painting but I've still got minor jobs to do first.

I tapped the flywheel rather than use nuts and fitted button heads (10.9 grade for shear strength). I used medium grade thread locker.

I should have some prettier pictures before long unless I've irritated Shaun burns by not having stuff ready on time .

[Warkton Tornado No.1]

Excuse the interruption, but whenever I’ve swapped rivets for high tensile socket screws, thus far, I’ve always managed to tap the actual flywheel centre boss to M6. This gives even more clearance & is also marginally lighter

Then it’s just a case of using high tensile button head screws with a dab of Loctite threadlock. As there is often the ring plate (as in the case depicted) additional washers are not required (IMHO)

However, if you are hamfisted, cannot drill & tap square & your test of the correct torque is by stripping the threads(!) then drill through & use nuts on the back....

[Warkton Tornado No.1]

I tapped the flywheel rather than use nuts and fitted button heads (10.9 grade for shear strength). I used medium grade thread locker.

Hah! Great minds think alike!