Sorry no Picts. yet... I ordered a card reader for like 3 bucks on Ebay to get the Picts. out of the phone. I'll update the picts when I get it.
Anyway alot got done in the past two rainy days. Split the cases, and finished the porting inside them. There is enough room now for two cranks (almost). I do believe I hit close enough to the 40% volume increase mark. With the cases empty I filled them both (OEM case, and modified case (i have two sets)) with mineral oil. The OEM held .75 Qts., and the modified held just short of 1 1/4. I had to refill the area I milled out for the Ruima jug as the boost port was MASSIVE on that, and it left a 2mm gap behind the Polini boost. JB wled, and ALOT of tink 1/8" holes for it to bite into, some re milling of the boost, and done.
When I originally set up the Polini I used a 3mm spacer (to save time) for the base, and had a 1.75 squish (sucky). From
http://www.onlinemetals.com/aluminumguide.cfm I bought an assortment pack of 4x4" sheet aluminum for spacers (jug base). So today I cut the spacer, and using a paper gasket between the spacer and the case, as well as an oem Polini aluminum gasket between the spacer and the jug I got a perfect .5mm squish. The paper gasket is bedded with OMC Perfect seal, and the aluminum gasket is bedded with Permatex Flange sealer. BULLET PROOF! I mover the exhaust port up 1.5mm, and 2mm wider on each side. The forward transfers I moved up 1mm, and left the rear transfers as is. This should raise the power band up in rpm, while still making power below the pipe. That was the time consuming part. It took all day to get the jug set, and mounted.
The fun stuff was in the cvt. I drilled 6 7/8" holes along the belts path (top, and bottom), and a series of 7-8 holes thru the bump out where the kickstart lever is mounted. Right over the Var. These along with the 6" hole over the clutch will let in enough air to keep it cool.
I installed a Stage 6 MKII instead of the Malossi Delta for various reasons... Mostly ease of tuning. Along with that I am using a Stage 6 race bell so again... Bullet proof. I am using the second strongest fly springs Stage 6 offers (orange), as well as a Malossi red Contra. w/ a Malossi torsion controller to shim the spring tighter. The reason for all the pressure on the TD is I have some NEW gears. I got my Polini instead of the Malossi primary gears, and Steve from Moped Hospital was generous enough to part w/ a set of custom cut secondary gears from back in his racing day. He tells me they never had a bike that could push these gears so they sat on the shelf for years. I promised I would not bitch... The OEM drive ratio is 10:1. I had a set of secondaries that gave me 8.3:1, and ran 3 kits that way. The Polini over reved at 12.5krpm. I ran out of gear... Installed the Malossi primary set 7.1:1, and ran off the speedo before again running out of gear. Now with the Moped Hosp. gears, and the Polini Primaries I have a final ratio of 5.75:1. I don't see running out of gear w/ that ratio. It will be NO wheelie popper but it MAY get the 90mph mark I want. The rest of the cvt is a Jasil var/7.5gr Jasil rollers (Damn best rollers I have used... NO wear visiable after almost 700 miles of breaking in the kit), and a Malossi Kevlar (of course) belt. The cvt is all an educated guess at this point because of the new gears so springs/rollers may be swapped out in testing.
Here's something just for Batts... In swapping the gears I found the main shaft on the secondary gear was TIGHT in the boss on the case. I actually had to tap it in. Then I couldn't turn the input shaft by hand. NO GOOD. Pulled it back out, and chocked it in a drill press. Using 2000 grit emory paper I hand lapped the boss, polished it out w/3000-5000-6000-#7 rubbing compound, and finally Dupont polishing compound. The gear dropped in. No play, and spins like a top. The thrust washers, and shims were replaced with new ones along with the seals, and bearings. I did have to use a point file on one of the secondaries as it was just a hair too tight. Now the whole deal spins like a new bike. Somewhere in all that is what I think Batts missed. Tight is great for lots of things but NEVER on a gear set.
Anyway I did have to shim my boss because the Malossi belt is .5mm wider. I also destroyed my cvt cover gasket so the kick start crown gear is hitting the drive face... Two-Three cover gaskets will fix that.And finally I am trying a new set of Boysen .035 reeds. I use .030 for most all reed engines but this one has a 15krpm red line so I believe the thicker reeds are needed. We'll see.
Thanks for the love guys!
Ps... The engine held pressure for 1/2hr w/o the carb or pipe. Tomorrow I want to test it with the pipe installed to verify the integrity of all the 25 welds. Thanks to my handy dandy TSG Pressure tester I can now do this test like a gentleman.
http://www.thescootergarage.com/
