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Post by 190mech on Sept 12, 2023 14:57:16 GMT -5
1100 is hard to find in thin sizes (.016), aluminum roof flashing seems pretty soft and is thin (.015), may be worth a try with copper spray on each side..  |
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Post by oldgeek on Sept 12, 2023 17:13:24 GMT -5
1100 is hard to find in thin sizes (.016), aluminum roof flashing seems pretty soft and is thin (.015), may be worth a try with copper spray on each side.. Found some copper in different thicknesses, cheaper than the 1100 too. Steel gasket was around .43 I may be going with something around .5mm to allow a thinner base gasket and still maintain squish. |
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Post by oldgeek on Sept 13, 2023 20:08:21 GMT -5
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Post by oldgeek on Sept 19, 2023 20:54:57 GMT -5
We have been steady at work but I have managed to get a few things done on this project. I cut the cylinder base down a little more on the lathe. I like the fixture I used this time around much better than using the four jaw chuck to grip the cylinder bore, less chance of scarring up the bore. I basically just trued up the base square to the top of the cylinder. I realized the more I cut the base of the cylinder, the closer the exhaust port comes to being uncovered when the piston is at TDC.
The copper sheet I ordered arrived so I cut a new head gasket from a .5mm sheet. I made some quick squish checks and have come to the conclusion that any squish under 1mm will have to do. All that is left to do is clean everything up, anneal the copper head gasket and put it together.
I have been watching a lot of videos of vertical Honda builds, mostly Taiwanese and have noticed those guys never seem to use any sealant on the base gasket. I may try the same this time, but most likely will at least use the copper spray on the base gaskets. Probably going to use some copper spray on the head gasket too, its good stuff.
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Post by oldgeek on Sept 22, 2023 11:20:44 GMT -5
Went ahead and cut a .8mm base gasket to go with the .5mm head gasket. Annealed them and pickled them to get rid of the fire scale.  |
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Post by oldgeek on Sept 24, 2023 15:17:35 GMT -5
Got the cylinder installed, squish is fairly even around .88 good enough for this build. Installed the crank seals, and did the final assembly of the gearbox with a gasket I cut. 6" red NGK plug wire threaded into the gearbox fill hole so I wont forget gear oil.  Cleaned up the rear brake hardware and installed. Cut a gasket for the intake and installed the intake but took it back off when I realized I could not install the water fitting in the head with the intake in the way. I dug out 2 Kymco rear wheels with tires. The tire in good shape needs a new valve, the other tire is almost worn out. Ill likely use the wheel with the worn out tire, I dont feel like mucking with these wheels and tires cause they are a real PITA. I need to order some of those gasketed washers from Grainger to use on the carter bolts and studs. I used some Air seal gas and oil resistant sealant on the 103cc setup and I could tell I needed something a little better. |
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Post by aeroxbud on Sept 24, 2023 17:12:32 GMT -5
Making steady progress. 👍
If the red wire helps to remember, then it's a good idea.
I have a similar nagging doubt with my Aerox project. I'm sure I changed the gearbox oil when I rebuilt the engine. But it was about six month ago. So going to change it again anyway before I ride it.
Better to be safe than sorry.
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Post by oldgeek on Sept 24, 2023 19:04:46 GMT -5
Making steady progress. 👍 If the red wire helps to remember, then it's a good idea. I have a similar nagging doubt with my Aerox project. I'm sure I changed the gearbox oil when I rebuilt the engine. But it was about six month ago. So going to change it again anyway before I ride it. Better to be safe than sorry. I am hoping to at least test start it by the end of this coming week. I may not have the cooling system sorted out but that wont stop me from doing a test startup. Hell the only video I have ever seen of this particular cylinder was built by tunescoot. When he finished the build he proceeded to rip wheelies in the road out front of their shop. Several passes were done and I noticed the cooling connections on the cylinder were not even connected! I wonder if anyone has ever successfully run this kit LOL! |
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Post by oldgeek on Sept 26, 2023 21:01:28 GMT -5
I went over to the shop around 6:30 tonight and to my surprise I got quite a bit accomplished. There is still plenty left to do before I fire it up. The sealing washers I wanted from Grainger are now out of stock until end of October. I ordered some from another place that I thought was US (Harfington) but it turns out they are China and 9 days for shipping. I just ordered an assortment from Amazon for $15 they should be here by Friday. The pipe went on with just a tweak to the bracket, the wheel and tire fought me as usual. I noticed the license plate on this scoot expired Nov. 2021, I cant believe it has been so long! I have the current sticker for the plate, somewhere. I was thinking of putting the water pump up under the right radiator maybe even under the floor board, is there anything wrong with that idea?   |
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Post by oldgeek on Sept 27, 2023 20:45:49 GMT -5
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Post by aeroxbud on Sept 28, 2023 4:28:58 GMT -5
Real bikes need kicking into life. 😉
Sounds like it's got good compression.
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Post by 808ministroke on Sept 28, 2023 18:34:14 GMT -5
Sounds like it was turning over very slowly like the starter motor didn't have enough power to overcome the compression, Or a week battery maybe. I agree with the previous comment above seems like the only way that things gonna start is by couple good kickss🦵💪💥💨 oh and a little starter fluid never hurts...
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Post by oldgeek on Sept 28, 2023 19:15:58 GMT -5
Sounds like it was turning over very slowly like the starter motor didn't have enough power to overcome the compression, Or a week battery maybe. I agree with the previous comment above seems like the only way that things gonna start is by couple good kickss🦵💪💥💨 oh and a little starter fluid never hurts... You hit the nail on the head bud, the long makeshift jumper cables I was using were the problem. First thing this morning I put the battery in the scoot and she roared to life! Do you have any idea where I should be on jetting with a 28mm PWK? currently with 50 pilot, 151 MJ, JJK needle, 2.9 needle jet, 3.5 slide, large pod style filter. |
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Post by oldgeek on Sept 28, 2023 19:53:41 GMT -5
In between service calls today I ran the scoot a couple more times. The carb is going to need a lot of tuning and I have no idea where to begin with the PWK's Currently has a 50 PJ and a 151 MJ. Using the large orange lawnmower airfilter setup like I had when I tried the PWK on the 103cc and fried the piston. I also reworked the bracket for the radiators, they are closer to the floorboard now. I mounted the pump directly below the right radiator under the floorboard. All hoses are ran and connected with the exception of the 2 cylinder connections. I had to remove the intake to be able to screw the fitting into the head and I need to find out what kind of sealant to use on the screw connections. I forgot to install an inline coolant sensor, so that needs to be done also.   Lastly I need to wire up the pump which may be a small issue because I do not use a key switch for this scoot. I have a starter enable switch which I could use but once the scoot is running you can turn the starter enable switch off and the scoot still runs. I can see myself accidentally turning the switch off while riding. I use a kill switch to turn the scoot off, I guess I could wire the pump into that. We have an install to do tomorrow at work so I doubt there will be any scooter related stuff done. I hope to finish the cooling system this weekend so I can try and ride this thing. |
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Post by oldgeek on Sept 29, 2023 19:32:54 GMT -5
I had some time this afternoon and evening to finish up everything needed for a test ride. I filled the coolant system and had leaks here and there without even running the pump. I replaced a clamp or two, tightened up the rest of them, no more leaks. I went to wire the pump and could not get the connector to plug into the pump. Upon inspection it appeared that the pump was keyed and the plug was not keyed. I finally realized that there was a plastic clip holding a seal in the connector, I pulled the clip out of the connector but still could not get it to mate to the pump. Then I pulled the seal out and the plug fit perfectly, that was an hour of my life I would like back!   I fired it up and intended to do a test ride around the building but it would not move, it seemed to be pig rich through the full range. I had the needle on the 2nd richest clip, I moved the clip to the leanest point and it ran much better. It was still rich down low even with the air screw all the way in but once I got past the rich spot it hit pretty hard. Willing to rev I saw 10K but I took it easy Lol! The highest temp I saw was 138F I am a little worried about screwing this thing up trying to tune. I have zero experience with LC and know hardly anything about the PWK carbs. DTS: September 29, 2023 6:00 PM Cylinder Type: Tadia 54mm LC Crank: Taidia Stroke: 52.4 Ex duration: 192 Xfer duration: 130 Pipe: TWH big pipe Intake: OkO Reed setup: S6 CF Viton Air in: Orange Mower Filter (large) Carb Type: PWK 28mm Slide: 3.5 Main Jet: 151 Pilot Jet: 50 Needle: JJK Clip Position: 5 Needle Jet: 2.9 Air Screw: 0 Variator: TFC Ramp plate: TFC Boss: 37 mm Shim: -0.1 mm Weight Type: Sliders Total Weight: 40.5 g Weight A: 5.5 Weight B: 8 Rear Pulley: TWH Contra Spring: White Malossi Clutch: S6 Clutch Bell: Piaggio Belt Specs:Malossi 6111153 734x18.2x30° Belt Wear: 0.1 mm Gearing: 10.61 Top Speed: 1 mph RPM@WOT: 1 plug: BR9HIX CHT WOT: 138 °F Launch: Poor Mid Pull: Very Good Ride notes: First Ride. Very rich off idle mid and top are strong. |
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Cleaned up the rear brake hardware and installed. Cut a gasket for the intake and installed the intake but took it back off when I realized I could not install the water fitting in the head with the intake in the way.
