let the games begin - R69s engine rebuild

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malmac
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Re: let the games begin - R69s engine rebuild

Post by malmac »

flyingtpot wrote:
Wed Sep 09, 2020 4:52 pm
Hi Mal,

Oops.... I meant to include the Sunnen part numbers of their portable mandrel drivers for your review. The P-180 and P-200 are the units to use in this application. The initial upfront cost of the tooling usually is the reason not to take this process path. Yet, it is an excellent tooling approach to have available especially if you have other uses for it in your shop.

Now that high quality carbide reamers are readily available, and the norm in some speed shops, I've tapered off on some use of my Sunnen equipment while switching over to reamers. Yet, there are still times when stones are the path to take. The Honall and Sidewinder are not for large bores (over ~35mm).
I followed up with the local suppliers and the cost is substantial.
Though it seems like an excellent product - I guess we have had our dollar values corrupted some what by cheap knock offs coming out of Asia.

The secret is what else could I use it for?

I thought I would get a price from an engineering shop to do this task for me and that will give me some idea of the relative merit of farming this task out. It may be the best end result.

Thanks for opening my eyes to this product.


Mal
mal - R69s
Toowoomba- Australia

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malmac
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Re: let the games begin - R69s engine rebuild

Post by malmac »

Today I started work on building a model crankshaft. The reason is I want to really feel how moving a given component impacts on the alignment of other parts.
My dummy crank does not have conrods yet but it should give you the idea of where I am heading.

Mal
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mal - R69s
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Re: let the games begin - R69s engine rebuild

Post by malmac »

The other project is dressing the front of the crankcase to remove a bunch of small imperfections.
I sourced a large sheet of 800 grit wet and dry. Glued it to a sheet of plate glass and dressed the front surface.
Quite happy with the result, here are a few pics.

Mal
MAL_0966.jpg
MAL_0964.jpg[attachment=2] MAL_0963.jpg
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mal - R69s
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malmac
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Re: let the games begin - R69s engine rebuild

Post by malmac »

Work continues on the crankcase.
Here is some work I have done on a couple of studs that needed attention.
The one that holds the gear box to the engine was just sloppy in the thread.
The one at the front of the engine I damaged the thread while removing because I did not realize that I had scuffed the end of the stud while retapping the thread for the stud that holds one of the barrels on.

Here are some pics which might explain what was done.
MAL_0986.jpg
MAL_0985.jpg
MAL_0984.jpg
MAL_0982.jpg
MAL_0981.jpg
mal - R69s
Toowoomba- Australia

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malmac
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Re: let the games begin - R69s engine rebuild

Post by malmac »

Went today and had a look at the Sunnen P180 hoaning system.
P180 hoane.jpg
I have ordered part of the system, but not the expensive universal joint driver.
My plan is to machine up a suitable alternative and test it for effectiveness before attempting to hoane the cam follower bores.

Also popped in to the BMW dealer and tested the fit of my butt on an R18.
Not everyone's cup of tea, but I like it.



Mal
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mal - R69s
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malmac
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Re: let the games begin - R69s engine rebuild

Post by malmac »

While I am waiting for the hoaning parts to arrive I got back onto the crankshaft.
The crankshaft is a new reproduction crank.
When I put it in the trueing stand to check alignment I found that while the runout was within spec the conrods when paired did not confirm that that the crank was correctly within spec.
So it needs a slight attitude adjustment.
To hold the crank while it gets talked too, I made up some aluminium blocks to hold it steady.

Mal
MAL_1013.jpg
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MAL_1020.jpg
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Re: let the games begin - R69s engine rebuild

Post by jwonder »

malmac wrote:
Mon Oct 12, 2020 3:20 am
Went today and had a look at the Sunnen P180 hoaning system.

P180 hoane.jpg

I have ordered part of the system, but not the expensive universal joint driver.
My plan is to machine up a suitable alternative and test it for effectiveness before attempting to hoane the cam follower bores.

Also popped in to the BMW dealer and tested the fit of my butt on an R18.
Not everyone's cup of tea, but I like it.



Mal
You look good on the R18! I have not sat on one yet, but if I do it may find a place in my garage!!!

Thank you for all your great posts on the forum.
James Wonder
Long Island, New York

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malmac
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Re: let the games begin - R69s engine rebuild

Post by malmac »

jwonder wrote:
Thu Oct 15, 2020 4:05 pm
malmac wrote:
Mon Oct 12, 2020 3:20 am
Went today and had a look at the Sunnen P180 hoaning system.

P180 hoane.jpg

I have ordered part of the system, but not the expensive universal joint driver.
My plan is to machine up a suitable alternative and test it for effectiveness before attempting to hoane the cam follower bores.

Also popped in to the BMW dealer and tested the fit of my butt on an R18.
Not everyone's cup of tea, but I like it.



Mal
You look good on the R18! I have not sat on one yet, but if I do it may find a place in my garage!!!

Thank you for all your great posts on the forum.
Well I had to put on my "CRUISER" face - its really serious stuff being cool and laid back on a cruiser.

I think I would struggle with adopting the correct attitude.

Still I do love the look of the bike, too bad about the weight, i had a hernia just looking at it. Did not try and lift it off the side stand. the salesman did offer me a ride which was nice of him.

All the best if you do decide to buy one. They look great.


Mal
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malmac
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Re: let the games begin - R69s engine rebuild

Post by malmac »

Well been away for a couple of weeks and got back into the shed today. Time to do some more work on the engine.
Two main issues on the plate.
1. Sorting out the reproduction crank and
2. Honing the bores for the over sized cam followers.

2. The parts for the honing system are in the mail so this week should see them arrive.
1. In regards to the crank.
The offset is out a little but first I want to look at the length of the crank to see how the conrods will sit in the cylinders.
Measured up the crankcase to get a figure on the cylinder offset. Measured up at 33mm. I assume that is the magic number but if I have it wrong please chirp up.
Here is how I measured the offset. Measured from the front mating surface.
wolfs crankshaft.jpg
Tomorrow I will measure up the crank and see what gives.
MAL_1052.jpg
Cheers


mal
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malmac
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Re: let the games begin - R69s engine rebuild

Post by malmac »

Work on the crank is progressing.

The alignment offset was .65mm when I started and now is well within the .2mm.
The next challenge is to get the runout at either end of the crank to within specs.
Currently front stated at .06 and I have reduced that to .05, so still lots to go to be less than .02mm.
crankshaft step 1.jpg
It just shows that reproduction parts are unlikely to be manufactured to the same quality as the factory was turning out in the 1960's. Yes there are exceptions for sure but I would have genuine parts over reproduction parts anytime.


mal
mal - R69s
Toowoomba- Australia

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