Building 1 engine from several brands parts
04-06-2010 | 01:13 PM
#1
Thread Starter
Tech Lord
Joined: Aug 2007
Posts: 14,044
From: Holland
Building 1 engine from several brands parts
I just got a box with all my old (broken) engine stuff, it was all examened by my sponsor in the use for devellopment/comparing their engine.If I could build up something for trainig, spare or as a rain engine.
I found the case of my old RB Xenon-R (Sirio based), I know it has runned just 6 or 7 liters before the rod broke. The crankpin was still OK end in good size and no play on the bearings so this must be a good start.
A good looking sleeve of a JP R01 and a fitting piston with a R7 rod must make a fit.
RB dos have some differences comparing standard Nova based engines and one of them is the location pin. A small cut on the opposite side is simple to do.
The hole in the case for the sleeve is 19.4mm while the JP sleeve is 19.5mm, I fixed an adapter to mount the sleeve in my drill station and with a piece of sandpaper I could grind it down to 19.4mm
When fitted it was clear the sleeve was sitting to low so from a 0.5mm thick plate aluminium I made a ring for under the sleeve which did set the sleeve almost to the right height looking through the exhaust.
RB has a crankpin of 5.02mm so a R7 rod with a 5mm hole will not fit. I have a dremel 5mm diamond grinding bit I have used before to do this job. Now it fits like a glove.
In the box also some heads made by my sponsor to fit Novarossi engines. It has an in one piece combustion chamber for a maximum cooling. It did not work that good because the chamber was to small and to much head clearance needed to be used. With a 10mm drill I could make it a tiny bit wider and straighter in shape to get more volume.
While I was busy I just drilled some holes to make it lighter, I did go from 70 gram to 65 gram, not that much and I think most racers do not notice that.
With a piece of solder setted the head clearance to 0.7mm to start with and mounted it all togeather.
OK, the stroke of the crankshaft does not fit the stroke the P/S set needs but 0.1mm difference (16.7 / 16.8) is not a huge difference
Now just to mount a clutch and give it a try.
I found the case of my old RB Xenon-R (Sirio based), I know it has runned just 6 or 7 liters before the rod broke. The crankpin was still OK end in good size and no play on the bearings so this must be a good start.
A good looking sleeve of a JP R01 and a fitting piston with a R7 rod must make a fit.
RB dos have some differences comparing standard Nova based engines and one of them is the location pin. A small cut on the opposite side is simple to do.
The hole in the case for the sleeve is 19.4mm while the JP sleeve is 19.5mm, I fixed an adapter to mount the sleeve in my drill station and with a piece of sandpaper I could grind it down to 19.4mm
When fitted it was clear the sleeve was sitting to low so from a 0.5mm thick plate aluminium I made a ring for under the sleeve which did set the sleeve almost to the right height looking through the exhaust.
RB has a crankpin of 5.02mm so a R7 rod with a 5mm hole will not fit. I have a dremel 5mm diamond grinding bit I have used before to do this job. Now it fits like a glove.
In the box also some heads made by my sponsor to fit Novarossi engines. It has an in one piece combustion chamber for a maximum cooling. It did not work that good because the chamber was to small and to much head clearance needed to be used. With a 10mm drill I could make it a tiny bit wider and straighter in shape to get more volume.
While I was busy I just drilled some holes to make it lighter, I did go from 70 gram to 65 gram, not that much and I think most racers do not notice that.
With a piece of solder setted the head clearance to 0.7mm to start with and mounted it all togeather.
OK, the stroke of the crankshaft does not fit the stroke the P/S set needs but 0.1mm difference (16.7 / 16.8) is not a huge difference
Now just to mount a clutch and give it a try.
04-07-2010 | 02:51 AM
#3
Tech Elite
Joined: Aug 2001
Posts: 3,278
From: Bavaria, Germany
Do not get this the wrong way, but I would be very surprised if this engine would make good power and run consitantly.
But, you never know.
Let us know how it went.
But, you never know.
Let us know how it went.
I just got a box with all my old (broken) engine stuff, it was all examened by my sponsor in the use for devellopment/comparing their engine.If I could build up something for trainig, spare or as a rain engine.
I found the case of my old RB Xenon-R (Sirio based), I know it has runned just 6 or 7 liters before the rod broke. The crankpin was still OK end in good size and no play on the bearings so this must be a good start.
A good looking sleeve of a JP R01 and a fitting piston with a R7 rod must make a fit.
RB dos have some differences comparing standard Nova based engines and one of them is the location pin. A small cut on the opposite side is simple to do.
The hole in the case for the sleeve is 19.4mm while the JP sleeve is 19.5mm, I fixed an adapter to mount the sleeve in my drill station and with a piece of sandpaper I could grind it down to 19.4mm
When fitted it was clear the sleeve was sitting to low so from a 0.5mm thick plate aluminium I made a ring for under the sleeve which did set the sleeve almost to the right height looking through the exhaust.
RB has a crankpin of 5.02mm so a R7 rod with a 5mm hole will not fit. I have a dremel 5mm diamond grinding bit I have used before to do this job. Now it fits like a glove.
In the box also some heads made by my sponsor to fit Novarossi engines. It has an in one piece combustion chamber for a maximum cooling. It did not work that good because the chamber was to small and to much head clearance needed to be used. With a 10mm drill I could make it a tiny bit wider and straighter in shape to get more volume.
While I was busy I just drilled some holes to make it lighter, I did go from 70 gram to 65 gram, not that much and I think most racers do not notice that.
With a piece of solder setted the head clearance to 0.7mm to start with and mounted it all togeather.
OK, the stroke of the crankshaft does not fit the stroke the P/S set needs but 0.1mm difference (16.7 / 16.8) is not a huge difference
Now just to mount a clutch and give it a try.
I found the case of my old RB Xenon-R (Sirio based), I know it has runned just 6 or 7 liters before the rod broke. The crankpin was still OK end in good size and no play on the bearings so this must be a good start.
A good looking sleeve of a JP R01 and a fitting piston with a R7 rod must make a fit.
RB dos have some differences comparing standard Nova based engines and one of them is the location pin. A small cut on the opposite side is simple to do.
The hole in the case for the sleeve is 19.4mm while the JP sleeve is 19.5mm, I fixed an adapter to mount the sleeve in my drill station and with a piece of sandpaper I could grind it down to 19.4mm
When fitted it was clear the sleeve was sitting to low so from a 0.5mm thick plate aluminium I made a ring for under the sleeve which did set the sleeve almost to the right height looking through the exhaust.
RB has a crankpin of 5.02mm so a R7 rod with a 5mm hole will not fit. I have a dremel 5mm diamond grinding bit I have used before to do this job. Now it fits like a glove.
In the box also some heads made by my sponsor to fit Novarossi engines. It has an in one piece combustion chamber for a maximum cooling. It did not work that good because the chamber was to small and to much head clearance needed to be used. With a 10mm drill I could make it a tiny bit wider and straighter in shape to get more volume.
While I was busy I just drilled some holes to make it lighter, I did go from 70 gram to 65 gram, not that much and I think most racers do not notice that.
With a piece of solder setted the head clearance to 0.7mm to start with and mounted it all togeather.
OK, the stroke of the crankshaft does not fit the stroke the P/S set needs but 0.1mm difference (16.7 / 16.8) is not a huge difference
Now just to mount a clutch and give it a try.
04-07-2010 | 03:14 AM
#4
Thread Starter
Tech Lord
Joined: Aug 2007
Posts: 14,044
From: Holland
Maybe next weekend I will give it a try, I will mount a clutch and can make a start in the backyard. You will hear more!
04-08-2010 | 02:04 PM
#7
Thread Starter
Tech Lord
Joined: Aug 2007
Posts: 14,044
From: Holland
No more stripping belts? 
Yes, that is an easy solution for the frontbelt which should we a standard in the kit, I am glad you like it. In the current days it is a shame that most people can not (or will not) fix problems by creating solutions than only getting option parts. Back in the days that was different, a lot of parts needed to be modified or home made.
This is just a funproject to see if it can be done and so far with simple tooling it is possible. I am sure the engine will run and regarding the current height of the ports I think it will run OK. These are just old parts, there is no investment and so nothing to loose but if it works I could arrange a new P/S set.
Yes, that is an easy solution for the frontbelt which should we a standard in the kit, I am glad you like it. In the current days it is a shame that most people can not (or will not) fix problems by creating solutions than only getting option parts. Back in the days that was different, a lot of parts needed to be modified or home made.
This is just a funproject to see if it can be done and so far with simple tooling it is possible. I am sure the engine will run and regarding the current height of the ports I think it will run OK. These are just old parts, there is no investment and so nothing to loose but if it works I could arrange a new P/S set.
06-01-2010 | 03:39 AM
#9
Thread Starter
Tech Lord
Joined: Aug 2007
Posts: 14,044
From: Holland
It did run fine for a short time, the piston did become very loose. In the beginning the piston did feel great but the sleeve was probebly from a broken engine and a tiny bit misformed that the piston did push back in shape.
The 1st impression was OK.
I have pinched it and need to run it in but did not have the time due races and work.
The 1st impression was OK.
I have pinched it and need to run it in but did not have the time due races and work.
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