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Post by billwill on Nov 11, 2023 6:10:00 GMT -5
Scooped up some parts and decided to finally pull the engine and crack it open. After much research and back and forth on things I landed on: - Stage6 Sport Pro MK2 cylinder - Doppler HPC full circle crank - Polini PWK 24mm carburetor Been taking a lot of inspiration from Pig's build here: 49ccscoot.proboards.com/thread/7736/project-race-pre-bugLooking forward to seeing what the Stage6 MK2 is all about. The kit is has a double ring piston but yields some impressive power and should be fairly reliable. This and a lot of other cylinders for verticals only come with 10mm wrist pins so options are limited if you run 12mm but it is what it is. Current state of things: bunch of little casting imperfections inside which I might take the time to clean up/smooth out.   I'm excited about the cylinder but also a little miffed on the quality of Stage6... its almost as if they didn't finish cutting toward the base of the cylinder and it wont sit flush against the cases. This kit is hard to find and I got the last one from Treatland so I'd rather just fix it myself with a dremel than return it.   Not much info here on the vertical engines so looking forward to getting into port matching the cases and seeing how that goes. Crank should be here middle next week so I have some time. With port matching, am I basically seeing where the gasket matches up to the cases and removing case material as best I can to make them match up? The vertical cases seem a bit more difficult or risky than the horizontals with less thick walls. Open to tips here before I dig in. Here is a pic of what's in front of me:  |
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Post by 190mech on Nov 11, 2023 6:26:38 GMT -5
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Post by billwill on Nov 12, 2023 20:48:57 GMT -5
Thanks 190, I have some JB weld sitting in the garage so I might make use of that when I get to port matching. I ended up trimming a bit around the bottom of the cylinder and it fits better now. There may be some more material that needs to be removed but I'm trying to be as conservative as possible. Trim and fit, trim and fit. Let me know what you guys think about what I did tonight. The gasket that came with the kit is not great, in that, there are some areas that intervene with the flow if I were to port match, and there are other areas that are quite far from the ports on the cylinder. I ended making a template with paper by setting it on the cylinder and etching a relief with a pencil. This is more of an exact mapping of the ports of the cylinder. This one still isn't perfect, so I may make another. I'd rather do less cutting on the case than more than needed.        |
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Post by billwill on Nov 13, 2023 19:28:51 GMT -5
Did some very minor port matching earlier but I don't feel comfortable going any further without backing the case halves with JB weld. I think my apprehension to use JB weld is half laziness/rushing and half lack of trust in it - although its never left me down. Is it really ok to trust the JB weld? Seems like I'll be cutting through the cases and into it quite a bit. Will probably slap some in tonight. 
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Post by billwill on Nov 14, 2023 21:59:22 GMT -5
Threw some JB weld on last night and started digging into the cases a bit more tonight. The shape of this is difficult to catch on camera but I’m not cutting directly downward into the case. Just smoothing things out so air and fuel doesn’t run into a hard edge anywhere. Not the most powerful porting job but it has to be better than nothing.    |
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Post by 190mech on Nov 15, 2023 4:09:58 GMT -5
Looking Good!  |
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Post by billwill on Nov 15, 2023 6:30:03 GMT -5
Looking Good! Thanks 190! I started with the small case half where there is more case material to work with in that cutout area. I'll be attacking the other half soon. Do you think it would be better to stay away from eating through the case and going into the JB weld or should I cut into the JB weld and try to match each half? Crankshaft, carb and some other bits will be here tomorrow  |
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Post by 190mech on Nov 15, 2023 17:45:42 GMT -5
Do your best to make smooth transitions even if it does get through the case and keep left and right side as even as possible..
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Post by billwill on Nov 16, 2023 21:22:44 GMT -5
Port matched the transmission side of the case tonight. Pretty pleased with the symmetry and even more surprised that I didn’t bust through into the jb weld. I may spend some time making them more aggressive but am leaning toward keeping as is. Crank and carb were supposed to be delivered today but are delayed in the mail. USPS is garbage sometimes.    |
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Post by billwill on Nov 18, 2023 9:26:24 GMT -5
Welp, USPS continues to suck and the crank, carb and some other odds and ends remains to be delivered. USPS says they will be here today but I'm not holding my breath. In the meantime, I knew I would have trouble running a larger intake with these Aerox wheels and had mocked up the rear wheel and MXS intake on the cylinder and case the other day. The 130/90 13 tire was just a tad too large to run with the intake so I found a cheap 140/80 13 Kenda tire on Amazon and put that on.  You can see how close it is. It's not nearly as bad as I thought it might be and I'm really happy with the overall clearances. And another thing, I've been doing some more dremel work, but this time not on the case. For whatever reason, this stage6 cylinder must sit lower than the MXS lineup and others because when mounted, it wouldn't clear some of the case. It hurt me to do this but I had to shave away a small piece of the corner of the intake to get it to clear.   |
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Post by billwill on Nov 20, 2023 21:47:03 GMT -5
Crank is in and hondabond is curing!
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Post by aeroxbud on Nov 21, 2023 6:30:12 GMT -5
Hondabond on a Yamaha! Sōichirō just be turning in his grave.  |
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Post by billwill on Nov 22, 2023 0:04:03 GMT -5
Hondabond on a Yamaha! Sōichirō just be turning in his grave. LOL call it yamahondabond, if you will. This goose is cooked.  |
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Post by billwill on Nov 26, 2023 14:34:22 GMT -5
Spent some time over the past few days getting everything back together and the engine put in the bike.
I picked up some odds and ends at the SSS black friday sale including an S3 throttle and PWK throttle cable. Glad I did that, because I got impatient and tried using my old throttle cable from my Dellorto carb and it was too short and hanging at 3k rpms... thought it might have an air leak LOL!
Trying to take it easy and figure out jetting since I'm new to PWK carbs but it seems close-ish, probably rich. Let it idle and warm up in the driveway for about 10 min and it only reached 135º or so CHT. I think this Stage6 display/unit reads low. With the Polini Sport kit I never saw it get above 290-300º.
I blipped it a few times just to get a sense for clutch engagement and power and holy cow - definitely has the power and upgearing may be more of a necessity than a nice-to-have.
Need to figure out a filter setup for this. I'm thinking I'll get a unifilter and JB weld it to the stock airbox or something.
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Post by bigmatthew86 on Nov 26, 2023 15:39:05 GMT -5
Send it! I want to see a video of it ripping.
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