"Fly" redux: Super Fly! Bugeye 94cc liquid conversion.

[oldgeek]

Somehow I missed this thread so I spent the evening reading it through. Very nice work, I am sure you will have a ripper when you are finished. Ill be watching intently

[Lucass2T]

This is my spacer/wedge setup:





Without spacer:


With spacer:

[fly]

Those spacers are rad, guys!

I got it nice and flat, will hopefully have the spacer finished this by Fri.

I might have another go at cutting the blank. did an oopsie and didn't account for the mounting screw that hangs off the front before I cut out off the bar. 🤦 So it's either make the one I have two piece, or cut another. Another cut will probably be easier. Oh well, jig is made, won't take long.

I've also realized I can makes some cross members for the table saw to use my router setup on. It's a heavy cast iron top. I'll be able to use it as a manual 2 axis router "mill." Should be handy for roughing in some parts, and surfacing Al.

[fly]

Don't be like me and do this. It's hard to get a picture with the spacer and the valve stacked out towards the camera. But shows the nature of the mess up and an idea how it will sit.

When I was looking at this I was using the small half as reference, just totally whiffed on remembering the front screw hole. But I was looking at it tonight, and I may be able to work with this.

[fly]

I haven't gotten out to redo the spacer, did a little filling, doing some filing tonight to flow the cases (using correct files, yes). Slower than the rotory tool but it's quiet and swarf doesn't go everywhere, and I can sit on the couch with the TV on in the background. 😅 Can't wait for things to warm up, this stuff gets easier when the garage/driveway is available. Things will get into higher speed pretty soon here, hopefully. Double entendre lol

[fly]

So this is pretty much what I'm looking at. I don't want to round over the boost much so it won't rob the other transfers. It's huge, and not subject to the limits of the other transfers. So that's just relieved a touch. Then there's some widening and redirecting of the intake, and aiming towards some channels to ease flow into the side transfers. Dropped the side port floors a bit, again oriented to direct air to the "scooped" shape of the transfers on the exhaust side.

I'm just going to smooth out the wrinkles with a drum and call it good. There is one area on the top of the intake I'm going to reduce and flow a bit.

Gonna do the final pass on the cylinder deck with a fresh bit. That'll flush up the proud JB from filling.

Will match the JB reinforcing around the crank halves, then get these cases painted up. Finish the spacer, then figure out the intake. Then time to install crank. Then gears, lots of new bearings need pressing in. After that I'll start electric system and fitment of radiators, etc.

[808ministroke]

Mar 16, 2022 1:25:03 GMT -5 fly said:

Don't be like me and do this. It's hard to get a picture with the spacer and the valve stacked out towards the camera. But shows the nature of the mess up and an idea how it will sit.

When I was looking at this I was using the small half as reference, just totally whiffed on remembering the front screw hole. But I was looking at it tonight, and I may be able to work with this.

looks as though there is one side of the reeds that are super lose to the wall of the case, may not allow the reeds there too open up all the way.
you may want to angle them in a bit more or less depending on what side I was even looking at. also maybe cons8der smoothing out that edge between intake and boost port while ur doing this stuff.
great job so far.

[x7rocks]

Jan 24, 2022 23:59:26 GMT -5 fly said:

The pipe! One of our members hooked me up with a very lightly used pipe. I'm not sure whether he cares to be identified or not, so I will withhold names for now. The only thing was a bit of surface rust, which was mostly caught in the clearcoat. That stuff is tenacious!

I wirebrushed it all off and re-torched the seams. It looks pretty good! It'll just be a pipe I wipe down after use, I don't think I want to coat it with anything. Nothing seams to hold up all that well for long, anyway. Just has a light coat of Gunzilla on it for now. (It's inside and Gunzilla smells good and not too strong).

You can name him don't worry, enjoying your build 😃

[benji]

Mop n glo floor wax actually works real well for pipes. It keeps the rust off and gives it a nice golden Patina.

[fly]

I've heard that about mop n glow! I think it was the fellow (aptly) named Corrosion that first made me aware of it. But it didn't click until I just saw that. I knew it was a floor product, but for some reason I was thinking, "was it Simple Green?" I was even looking at cleaning products in the store the other week trying to remember what they heck it was. lol. Thanks!

808ministroker, yes I agree. Those pics were before this last shaping. The petals should have good clearance, especially with the spacer + the fact the vforce reeds don't need to open as wide.

X7 hooked me up with the pipe. 😅😅😅

[fly]

well I just wrote out a long post, accidently refreshed the page, and lost it all. 🤦

Long story short, had to cut down deck further than wanted to after router flub (forgetting to latch router base closed after seeing depth - not that bad, but still). So today I need to slap the crank in and cylinder and see where everything sits. I may need to order a thicker spacer.

I realized I *should not* use titanium as a spacer metal. It's too hard to be a abutting the aluminum cylinder skirt. It could potentially wear into the skirts with vibration, time.

I failed to make a reference point to mic how much I've actually taken off. I regret it SO MUCH. No idea how much I've taken off total now, must be closing in on 3mm, guessing 2.5-2.7mm.

Also was saying, if I could start again I would do a lot differently. may order a spare case set to start prepping if this setup isn't robust enough. would have just used JB Weld to smooth deck, been reading some hot rod guys use it to build up cylinder deck. would make bore a little tighter. would mill crankcase mating surfaces instead of JB experiment. although I'm still interested to see how that will work.

oh well, onwards.

[fly]

Well, I've got some 2.5mm spacers being cut, and have this ignition backing plate being zipped out as well. $29 minimum order, so even with several spacers I had a lot of order space left, 2 of these coming. One is 1mm, the other is 0.6mm. Basically thick gasket thickness. We'll see if I can get everything installed without bending it. lol.

Getting everything faired. Doing/finishing some fairing of some JB steel stick I used on top of the JB well supporting the transfer on the stator side, melding lines. Hope to be painting cases by tomorrow. Then, finally, I can actually start on assembly. Imagine that.

[benji]

Mar 21, 2022 7:55:28 GMT -5 fly said:

I've heard that about mop n glow! I think it was the fellow named Corrosion that first made me aware of it.

Joe (Corrosion) was a very good friend of mine. He developed quite a few techniques that lots of us use. He was a 2-stroke Assassin.

[fly]

Mar 23, 2022 16:11:44 GMT -5 benji said:

Mar 21, 2022 7:55:28 GMT -5 fly said:

I've heard that about mop n glow! I think it was the fellow named Corrosion that first made me aware of it.

Joe (Corrosion) was a very good friend of mine. He developed quite a few techniques that lots of us use. He was a 2-stroke Assassin.

As was I, I was one of the founding moderators. But I did not know him beyond the forums. I'm discerning from your use of tense he's no longer with us. That is sorry news, to be sure. He was always a paragon of good advice. Most of my common procedures are from his advice, as well. And they've been right on. Grey Permatex forever.

[benji]

Mar 23, 2022 16:36:25 GMT -5 fly said:

Mar 23, 2022 16:11:44 GMT -5 benji said:

Joe (Corrosion) was a very good friend of mine. He developed quite a few techniques that lots of us use. He was a 2-stroke Assassin.

As was I, I was one of the founding moderators. But I did not know him beyond the forums. I'm discerning from your use of tense he's no longer with us. That is sorry news, to be sure. He was always a paragon of good advice. Most of my common procedures are from his advice, as well. And they've been right on. Grey Permatex forever.

I knew him personally, but I met him in the forums. I'm not sure of his exact fate, but he was very sick the last time we spoke. I got the distinct feeling it was a goodbye call. His build threads are still here, tho.