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Post by 90GTVert on Aug 16, 2023 17:21:41 GMT -5
I TIGed all the way around the other side of the flange to be sure it winds up sturdy. The weld didn’t appear to cause any trouble with fit into the pipe, but just barely disturbed a bolt or two. I did some quick passes in the lathe that didn’t leave it pretty, but it works. I faced the whole thing off as little as possible to get it flat. I was happy to see that it wasn’t way off square so it didn’t need much to true it up. I didn’t wanna figure out how to calculate positioning for an o-ring groove or have to setup the part again so I mounted a Sharpie in a tool holder. Wound that in till it left a mark at 38mm ID. Aligned a cutter with the mark and went for it.
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Post by aeroxbud on Aug 17, 2023 4:12:27 GMT -5
Only a few years ago. You wouldn't of dreamed you would be making stuff like that. Really nice job.
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Post by 90GTVert on Aug 17, 2023 7:25:39 GMT -5
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Kaos
Scoot Enthusiast
Posts: 185
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Post by Kaos on Aug 17, 2023 10:10:00 GMT -5
Dang dude, thats some nicely done fabrication! I'm jealous!
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Post by Lucass2T on Aug 17, 2023 11:50:35 GMT -5
Over 2100 miles. Im impressed!
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Post by 90GTVert on Aug 17, 2023 18:21:34 GMT -5
I put masking tape on the flange and bolted it on. The port was off center. Not surprising. I used bolt holes for the center when I started drilling the port and then had to adjust one bolt hole later so it had to be off. Didn’t worry about perfect, but better. I cut to near port match, but left some room because there’s so much blending. There’s still more to be done, but my aunt fell for the third time in about 5 days and I had to go take a door off to be able to get her out of the bathroom and lift her into a chair. She’s about 300lb so this is getting old fast… plus the last time was 1:30AM. I don’t mind helping but she’s got 3 children and even 2 30 year old grandchildren that live upstairs in her house and I’m doing all of the lifting with only my 75 year old father that’s lucky to get himself up and moving to help a little. I think she needs to go to the hospital or doc or something. You’re only gonna fall so many times before you really get hurt. Anyway, not a ton left but I’ve put enough work in this piece that I don’t want to screw it up at the end from being tired and frustrated.
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Post by 90GTVert on Aug 18, 2023 19:17:37 GMT -5
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Post by oldgeek on Aug 18, 2023 19:31:01 GMT -5
I finished up the matching and blending today. Didn’t take the steps to polish it correctly, but maybe close enough that if the S6 exhaust still doesn’t do much for me I won’t get questioned about flange smoothness or quality. Looks really good from here!
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Post by 90GTVert on Aug 20, 2023 11:20:56 GMT -5
I've been taking measurements of the piston and cylinder...
Brand New Clearance = 0.0028"/0.071mm to 0.0034"/0.086mm End Gap = 0.006"/0.152mm
469 Mile Check Clearance = 0.0045"/0.114mm to 0.0049"/0.124mm End Gap = 0.010"/0.254mm
2,154 Mile Check (Now) Clearance = 0.0049"/0.124mm to 0.0052"/0.132mm End Gap = 0.012"/0.305mm
The cylinder hasn't worn more than 0.0001"/0.003mm in any of the measurement I took at the last check. The piston accounts for most of the clearance change, having worn 0.0003"/0.008mm in 1,685 miles.
Much more wear occurred in the first 469 miles than the last 1,685 miles. The cylinder has worn as much as 0.0003"/0.008mm total since new, at the top of the bore. The ring continues to wear, but has slowed since the first check according to end gap. The piston wore 0.0018"/0.046mm total, with 0.0015"/0.038mm from the first 469 miles and 0.0003"/0.008mm in the last 1,685 miles.
I didn't expect this little wear. My TPR continued to wear everything over time. Same deal for the iron stuff that I have had many more of. This seems like the parts wore in quite a bit together at first and then wear tapered off drastically.
The piston ring definitely should be replaced. Wear in the cylinder since the last check is at the top of the bore and the ring is now double it's original end gap.
I'm not really sure what to do regarding the piston. I have a C piston here (currently the stock A). With the C piston that measures 2.045"/51.943mm, I could take clearances down to 0.0025"/.0064mm to 0.0028"/0.071mm which would actually be better than brand new. Mine has never matched Malossi's specs of 0.048 to 0.056mm / 0.0019" to 0.0022" and others tell me they had larger clearances as well.
The C piston sounds better if only clearance values are considered. Looking at how much it wore breaking in vs settled in, I wonder if I would just see more wear right away. If just the piston and ring wore quickly at first, not a big deal. Most likely it would get to a "comfortable" size and slow down if data so far tells the story. I don't want to wear the cylinder more quickly though. That wore basically double in the first 1/4 of the mileage than the last 3/4. Would it wear quickly again with a fresh ring and less piston clearance?
I'm leaning toward replacing the piston to get nearer spec, but the wear pattern is making me second guess it a bit.
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Post by jackrides on Aug 20, 2023 19:34:59 GMT -5
Beautiful port work! Your Aunts kids and grand kids need to be professionally shown (home health care thru your county for a visit) and then when the pro is gone, a kick in the ass.
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Post by oldgeek on Aug 20, 2023 20:39:53 GMT -5
................ Would it wear quickly again with a fresh ring and less piston clearance? I'm leaning toward replacing the piston to get nearer spec, but the wear pattern is making me second guess it a bit. Tough choice. Maybe just re ring original piston, seems to be wore in good. Once you move to a "C" there's no turning back?
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Post by 90GTVert on Sept 7, 2023 16:56:09 GMT -5
I wound up using the C piston. It’s more correct by clearances so fingers crossed that it doesn’t wear quickly again. The end gap was 0.008”. Spec is 0.006”. Squish set to 0.58mm with 0.55-0.6mm spec. Didn’t feel any unusual play in the crank/rod so it only got a quick inspection. Cleaned and regreased the whole CVT. Swapped out the CVT cover bearing. It wasn’t awful, but I felt a little grinding and it made noise when turned. I had a rubber seal bearing waiting anyway because the rubber sealed bearings worked much better for me than metal shields in Chinarelli covers. I pulled the gas tank out to repair a broken tab on the frame that my homemade storage box mounts to. Replaced fuel hose and filter while I was at it. I was planning to weld a new shock mount on the frame for the beefy 1200# shock. It actually fit with just grinding off where the bushing protruded though. I’m curious to see if this monster changes how much it wheelies. Ultimately I think it would need a stretch to stay down, but if the shock did make it less wheelie prone it’s a way easier swap than an engine mount to go back and forth since sometimes I want to wheelie and sometimes I don’t. It is about 1.25” shorter, but it really shouldn’t sag much with weight on it so I’m thinking actual ride height will be close. I put a couple of tie down hooks on the steering stem. Ryan gave me a few, but they were too small for the 10mm bolts so I picked up larger ones. OC Bikefest is the 13th-17th so I’m trying to get it up and running and have some time to break in the piston kit a little. Practice launches a few times cause it’s been awhile and leaving Harleys at lights was the most fun I’ve ever had with a scoot. Ryan is gonna join me this year too. Trying to get him to bring one of his many bigger bikes and come out and ride somewhere another day with me and hopefully my sport bike friend as well. I think we’d all have fun whether going back to OC, cruising the swamps or whatever.
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Post by 90GTVert on Sept 9, 2023 15:48:16 GMT -5
I changed gear oil, took care of odds and ends and repacked the silencer, replaced all o-rings, and made a new clamp out of stainless. The clamp was a little short, but a few washers and a longer bolt cured that. I took the first gentle ride yesterday. Well… I was gentle with the throttle. “Rear shock” is an excellent way to describe my new 1200# suspension component. I rode a small bike with a steel bar in place of the rear shock in my 20s. Harsh, but doable. At 44… backroads feel sorta like if you imagine someone hitting your spine upward with a mallet. Not to leave out, but off the seat and it felt like scoot off the ground at times. That thing doesn’t urge even with a 300lb dude plus gear on it. Normally I think they overrate scoot shocks. I think this thing may actually be a million pound shock. But… will it control wheelies better? I rode again this morning and it will certainly still hop. Feels different now with just front motion and no compression at the rear. I rode around for a bit to break the new piston kit in a little. I was taking off as easy as I can near an expensive hotel and some guy walking a small dog looks at me and shakes his head. Now you’re gonna learn. If you think that sucks, check out wide open. 😜 I got to business later. Turned on the dragy and sat on the front of the seat. What I found out is that I can go full throttle pretty quickly now. The problem is, it’s just bad starts and not an accomplishment with the new monster shock. I managed to average 2.35 60ft… but good runs with me rolling in slower were as low as 2-teens and generally averaging 2.3s. This is poor response and/or clutch setup, possibly paired with a little belt slip as it starts going. I’ve had it try to toss me off the seat in the past so if all was on point it should not let me get into it quick without incident or 60ft should be noticeably better. 1/8 mile is about three tenths slower than best averages. I think RPM may be a little low, but close. Haven’t had time to go over video and grab that info. I’m gonna remove the chiropractor from hell and go back to the old shock. Then I’ll see what’s what. I think it will be the same story. I also noticed that the engine still easily pivots. I thought the rear shock being stiff May damp that a bit, but I’m not sure that it’s done anything. Drilling the motor mount cups to take bolts instead of springs would prob be the answer there. I just wanna get it back to comfortable and roughly how it was running, before the bike show.
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Post by 190mech on Sept 9, 2023 15:59:50 GMT -5
That new shock appears to be for a linkage type rear suspension MX bike, short travel and stiff spring..
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Post by 90GTVert on Sept 10, 2023 5:29:59 GMT -5
That new shock appears to be for a linkage type rear suspension MX bike, short travel and stiff spring.. Yeah, it's not the sort of thing that I really thought that I should use. Some time ago I was watching vids of my scoot vs racers and noticed that mine extends the shock back up as I take off and racers that launch well have little movement. I thought if I put something very firm on there that didn't sag much, that maybe it would improve launches. The idea was to go stiff, but not as bad as a solid steel so I could use it. I think it's very near a solid bar. Went a little overboard. Regardless, it's not doing what I hoped AFAICT. Currently considering taking T2 to a 9/11 ride on the Ocean City boardwalk. $10 donation to enter and there's a memorial service at the end. It's basically hundreds of Harleys and little else from anything I've seen in the past. I'd like to ride the boardwalk and I'm happy to be the one totally different thing there. Problems are; it's a drawn out event with registration and lining up starting 2.5 hours before riding the boardwalk. It's a 9/11 memorial, so I don't know if it's mostly Harleys because of some patriotic thing (as if their stuff isn't made in China now too) or if that's just because Harleys are everywhere. In addition, I see the Harleys revving and stuff... but maybe there's a limit on a memorial parade and you can't put me at 10MPH in front of crowds on the boardwalk (or all alone for that matter) and think I'm not gonna hop and rev it. I don't mind pissing people off in general TBH, but I don't want to be disrespectful to a 9/11 ride and I know that I don't just creep around and slow roll. Could be that no one cares or they're up for it, IDK. Plus, I don't know how long before OCPD intervenes when some jackass is playing on the boardwalk. I'd really like to ride the boardwalk and this is the only event that lets bikes do that. Could take the TMAX so I can't do anything but rev like the Harleys I guess, but I'd have more fun being on the small scoot that's nothing like anything else around. I'm probably gonna pass. Don't wanna spend a couple of hours waiting just to get booted out immediately and acting like I have good sense would only be an act and can only last so long. lol
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