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Project Hercules Chopper Build
เข้าร่วมเมื่อ 2 ส.ค. 2012
Random vids on making a chopper! First the engine, made from a few bits left over from a Bristol Hercules aircraft engine.
Next up the gearbox, with no actual gears but two speeds. Intrigued? Best get watching then!
Plus a few bonus CNC conversion threads...
#engine #enginebuild #engineering #chopper
Next up the gearbox, with no actual gears but two speeds. Intrigued? Best get watching then!
Plus a few bonus CNC conversion threads...
#engine #enginebuild #engineering #chopper
Slow Progress on the Decompressor.
Slow going machining an old valve down to size, it's very hard! Driving between centres has also been a pain to set up, but Bob had worked his usual magic.
#engine #engineering #chopper #motorcycle
#engine #engineering #chopper #motorcycle
มุมมอง: 748
วีดีโอ
Gearbox Mounted 💪
มุมมอง 3.5Kวันที่ผ่านมา
I don't know why, but the job of drilling the gearbox, the mounting plates and then fitting it all to the bike was heaving me worried. I'd been putting it off for too long so Bob gave me the nudge I needed and off we cracked. It was quite straightforward in the end and I'm pleased with the results. 😁😁 #chopper #engineering #gearbox #motorcycle
5 minutes in the shed - check it out...
มุมมอง 631วันที่ผ่านมา
youtube.com/@suzukisav?si=hERBCc48xPdEXsdJ
Morning update - it's all to play for 😁
มุมมอง 1.4Kวันที่ผ่านมา
Ramblings from the early morning to kick start the long weekend. I think the gearbox mounting is long overdue so will maybe tackle that today. That shaper really wants some attention though, a working motor and new belt will give it a new lease of life. #chopper #engine #engineering #shaper
One down, one to go.
มุมมอง 1K14 วันที่ผ่านมา
Light at the end of the tunnel, just one more operation and the spark plug holes are done. 💪 #engine #engineering #head #chopper
Minor problem to solve
มุมมอง 1.3K14 วันที่ผ่านมา
Never easy is it? I suppose there's only one way of doing something right, but a million ways to do it wrong! A simple operation to make clearance for a spark plug socket had turned into a major pain. But it looks like it'll be alright in the end. Just takes a little more time. Again. 😁 #engine #chopper #engineering #head
Rev counter says no!
มุมมอง 7K21 วันที่ผ่านมา
Final experiment with sprocket sizes for the Dynastart. It looks like a 19T sprocket is the optimal size, allowing the Dynastart to run at full speed.. Around 400 rpm cranking speed before we drop the decompressor. I'm happy with that. As for the valve we have kicking around, whether it's sodium filled or not remains mystery. #engine #chopper #engineering #head #custom
Could this be re-purposed?
มุมมอง 1.1K21 วันที่ผ่านมา
If this works it'll be an amazing coincidence! An old valve of unknown provenance that's sat on the mantle piece for years looks like it could be the right diameter. it will still need machining to the right size, and that will be interesting as it could be hardened - but it could save as lot of time. Hmm.... #valve #chopper #engine #engineering #head
Fitting the head & new sprocket
มุมมอง 2.6Kหลายเดือนก่อน
As requested here's a slightly longer video, a time lapse with some rambling voiceover. I quite enjoyed doing the commentary so I may do another, depends who likes it 😁 A good couple of hours tinkering. #chopper #custom #engine #head #motorcycle
A quick thanks while I fetch a tool
มุมมอง 792หลายเดือนก่อน
Lovely spring morning and while I'm getting the ring compressor from the shed I thought I'd waffle on a bit. If time and life allows the engine will be back in for another spin test later this weekend. #thankyou #spring #chopper #engineering #custom #engine
Not quite a valve seat. Almost. 🤔
มุมมอง 1.3Kหลายเดือนก่อน
I've only been away for a couple of days and the shed fairy has been really busy! The seat for the (not a) valve has been machined and so has the centre of the (not a) valve stem. The decompressor is effectively the same shape as a traditional poppet valve but it's not a valve. Confused yet? #chopper #engineering #custom #engine #head
Test of the new head decompressor flow
มุมมอง 1.9Kหลายเดือนก่อน
Last of the weekend, a trial fit of the head now that the decompressor holes have been bored. Plenty of gas flow and a good rotational speed 💪 Just a case now of removing the head and finishing the decompressor itself. #chopper #engineering #custom #engine #head #motorcycle
Heading in and out.
มุมมอง 4.5Kหลายเดือนก่อน
We're getting pretty slick at fitting the cylinder head and removing it again. The new head fits a treat and has good compression. The Dynastart has a slightly easier time now but still isn't up to the job, so we'll crack on at planned and make a decompressor. At least we know not where we're going, and after opening the holes in the head we can treat again. Lots of work with not much to see, b...
Heads up!
มุมมอง 916หลายเดือนก่อน
Head finished as far as possible for a trial run. A job for the weekend 💪 We'll know soon enough whether the starter motor will be strong enough, though I suspect we'll need to make and fit a decompressor. #chopper #engineering #engine #head
Groovy Adult 😁
มุมมอง 1.1Kหลายเดือนก่อน
Finished the 5° tapered ring lands and what a job that was! Took quite a bit of setting up by Bob, excellent job. That finished head being tested with the Dynastart it's so close I can smell it. 💪 #chopper #engineering #engine #head
Chains to length and gearbox mounting
มุมมอง 2.5K2 หลายเดือนก่อน
Chains to length and gearbox mounting
Nice tip! I used to file 2 or 3 grooves lengthwise on a bolt to do that.
this video would have been the perfect opportunity to demonstrate how the sleeve valve worked.
I think I explained it in the videos where I set the valve timing.
How much power does it require to move the sleave, compared to compressing valve springe?
A lot less, though I don't have any figures to support that. The drive is very smooth in comparison, there's no cam so there's no 'snatch' as the cam goes over the top. Sleeve valves tend to be a lot quieter in operation for the same reason.
Found your later videos so I came back here to start at the beginning, did you make your own patterns for the casting and what alloy mix have you used please?
I employed a pattern maker - which was a mission in itself as they're a dying breed! From memory it's LM25. The same factory cast a set of Aston Martin gearboxes in the same batch. Very early updates are on www.sophiewhiptank.com - somewhere!
Yep I was a pattern and die/toolmaker for small size aerospace, hence the curiosity, thanks
Can't you unharden the valve with a little heat, then reharden after machining?
We did consider that, but without knowing the composition of the metal is a bit hit & miss. It's cutting reasonably well as long as we stick to light cuts and exercise patience. 😁
Getting closer.
could you number your episodes so that binge-watching is in sequence please?
Already ahead of you. Here's a handy playlist of all the videos in time order. Any new content added to the end. th-cam.com/play/PL4O8wDMdiNDjA540eUYA1Z6DVrqxxhz5d.html&si=sjIHdL9J4MnrZB2e
@@StoneEng many thanks. I'm in for a good weekend. :)
Oh, that’s pretty cool. What kind of motor is that anybody answer?
Have a look through the other videos on the channel. It's all explained in detail.
When I saw that XS650, I pictured an xs1300, with two banks of aircooled twins. A v4, like the vf750... Maybe I should tell Allen Millyard, he's gotta be running out of ideas!
Next up is a 700cc V4 2 stroke based around a pair of RD350s. Phased transfer ports to increase efficiency. It's not made it to the drawing board yet, but needs to be done.
2 different chains running 2 different speeds are going to wear at 2 different rates. You might have them close right now, but after only a bit of running time you won't be able to get an acceptable adjustment on both simply by moving the rear wheel. You need to have a chain idler/adjuster on each chain run. Oh, I forgot, this is just a show piece and long term service really isn't a consideration at all. Never Mind. 😉
I hardly ever adjust the chain on the Blackbird, the tolerance i in tension s huge. I really can't see differential wear being a problem. I'll let you know after the first 100,000 miles. 💪
@@StoneEng 😅
Wot kind of engine is that?
Watch the other videos when you get chance, it's all explained in detail. 2796cc sleeve valve single.
That thing is cool👍👍👍
I was thinking about it more, the crankcase pressures will probably be very high, with the comparatively small ventilation hoses. On a radial engine there are always pistons going up when going down, so that's not a problem... a engine compression tester is a gauge with valves, for peak value readings, so connect a compression tester to the crankcase. Connect it directly to the crankcase, maybe off the vent hoses, but immediatly next to the case. That will tell you exactly how much pressure the crankcase experiences. (with the single vent filter, i bet you'll see peaks over 40psi when idling, worse with loose rings, but that # has nothing printed to verify it, it's just a guess from my experiences with many cars)
Haha, the gearless gearbox!
Those valve ports are huge! I wonder what it makes for hp & tq on a dyno...
If I ever put it on a Dyno I'll let you know.
@@StoneEng I'm guessing 73hp & 102lb/ft of torque, at the rear wheel. i get somekinda prize for being the closest, right?
Why not. Signed set of plans to the winner. 💪
needs Coffman start!
Such awesome work, it's a shame it's being built into a chopper though.
Out of interest, what would you put it in?
@@StoneEng Something that's not designed to be terrible to ride. Something with suspension, geometry that makes it handle well, and comfortable to ride. Almost any motorcycle design that's not a chopper or bobber.
I think that's a great platform to showcase all that cool stuff.
Me too. If I want to go fast and enjoy the ride I'll take my Honda Blackbird out. But the project isn't about that. However well the Honda handles, it will never be cool. P.H. is intended to be cooler than penguin piss 💪 I hope we're getting somewhere near? 😁😁
You will need some sort of adjuster to lock the gearbox, otherwise chain torque will pull it
Just tuned in.. WTF IS THAT..!!! WOW.... Made in England baby....
I have a huge electric motor under my bench...
I may be in touch. 😁
With the government trying to bring in type approval owning and riding custom builds may be a thing of the past , get your beast running before it's to late....
That has got to be the best breathing head I've ever seen.
what are your plans for brakes?
Putting a caliper on the rear sprocket, possibly both sides to make it 'triple disc' 😁
Great work,
Check the physics, your gearbox will pull back towards the rear wheel as your gearbox sprocket is smaller than your clutch, this happened on my pre unit British bikes. They would pull up the primary tight, stopped it when I would wind the play to push the box away from engine. Worth looking out for.
Thanks. I'll need some time to digest that nugget. In my case there are no gears, both clutch and sprocket run on the same shaft. Not sure if that makes any difference? Anyway, I'll watch out for it for sure.
Must have a mind melting amount of torque to need two chains. That back tyre is going to be toast
He obviously can explain it better than I can, but the reason for two chains has something to do with changing the gears when shifting.
nice work 👍
Great progress! Enjoyable to be this close, couple of OBS if I may … top of gearbox , maybe a stud between both sides with a solid spacer added rigidity? Possibility of a modern coil pack ( ugh) the advantage is you only have to route small signal cable(s) as the coil sits on the plug(s) have used ones from Ford Fiesta before , probably even smaller now. On a previous turbo bike build I used some nice st/st 303 pipe to form a conduit , there was enough room to run an oil supply pipe and two sensor cables inside .
Thanks. I thought about using coil overs but they look a mess and I've seen a few fail. I was thinking the same about making a conduit, but using copper central heating pipe instead. I reckon the gearbox casing is rigid enough, I can't see a cross piece adding anything to the rigidity. But it's easy for me as I can see it properly, as opposed to watching the videos. 😁
@@StoneEng good news, I bent some inch stainless bars up long ago , got some silver sand , oven dried it , whittled some end plugs and hammered then in , bent them on my conduit bender with a 5’ scaffold pole , bars were perfect but the bender was never the same 😀
Can't wait to hear this monster. Thanks for sharing :)
UNF is a great shout. Metric mounting bolts vibrate loose with the coarse pitch. Unless you use nylon nuts etc. have you considered torque pull on the primary? Is there enough friction to hold the gearbox in place? On a pre unit triumph for example they have adjusters, similar to the chain, to hold the gearbox in position and allow adjustment.
@@Turnipstalk Good point. And I'm assuming a metric fine stainless steel bolt is significantly cheaper than a UNF or CEI bolt too. 26tpi bolts in stainless are incredibly expensive now, as I recently found out!
@@Turnipstalk I lost a petrol tank stud last week on on the motorway. So this weekend was me, a lathe, some stainless and luckily my 3/8" 26tpi die! I had 2 stainless nuts left in my drawer too. Saved the day.
I reckon using 12ga cartridge start and hammer , be cool when leaving pub
love the videos
Why are you using 2 chains? If i may ask? To keep it straight with all that torque?
See my other videos explaining the gearbox. I can achieve two speeds by using two chains & different sprocket sizes on each side. 💪
Can't wait to hear this thing run
Same here
Nice
Hi, mucho impressed! 1 question, is that a belt drive Commando clutch?
And another question, where did you source the dynastart ?
Yes, Norton dry clutch from www.norvilmotorcycle.co.uk/ and the Dynastart came from www.woodauto.com/group/40/Dynastarters .
Don't change a thing, it's refreshingly calm, pleasant and informative as it is.
very cool :3
Just found your channel and subscribed. Very nice old machine. Nice work
Never seen a shaper quite like that one
Quick silly question; why grind the valve to fit the guide, rather than make the guide to fit the valve? The valve stem is already a precision-ground diameter. The guide will not be subjected to much cyclical / reciprocating movement as it would in it's previous life, and the guide can be ordinary EN8 for it's purpose. Will you be fitting a sleeve round the decomp ports to prevent oil contaminating the plug insulators? Will you be using a 'Wasted/Idle Spark' ignition coil? Seems like an elegant solution, (that you have probably already thought of), with lots of coils available on the market. (Not telling you what to do, just musing...)
I would have done that but the valve stem is far too thick. It would break into the vent holes and the valve works drop out. Good thinking though.
The way you make your videos is just perfect. Don't change anything. ❤
Surely you’ll need to cut a keyway on something, the shaper would be good for that.
A keyway - or even a keyring! As long as it's something for the bike. 😁
I like this channel because it’s a completely different format from everything else I watch on TH-cam. Keep doing what you’re doing!
I like your updates as they are. No enoying music, straight to the point and no bollocksy waffle. Looking forward to the big start up keep it up.
Thanks for making me properly laugh it loud - it's ALL bollocksy waffle! 😁😁
Just carry on as you are sir.
Someone said to me, a shaper will make anything, just not money! 😂 With the motors, electric motors never die. There's a good rewind place in Burton on trent. 👍
Ah, I'll look into that. It would avoid having to make a new motor fit. Cheers!
@@StoneEng they usually just need new bearings in the end plates, and maybe a capacitor or starting mechanism service. Very simple things really.
@@suzukisav sure. New bearings, windings, start capacitor, magnets and a case. 🤔 Trigger's broom springs to mind 😁
@@StoneEng 😂
Looking good.
New plan for the anticompressor... have a hydraulic chain tensioner on the slack side of the chain with sufficient travel to have a drive side that tightens the chain by moving towards the camshaft. i think the new parts will all fit on the timing cover, but the cover might need a cover.
I havent used a shaper since the 80s. That was a very large Kearney & Treker
You sure it was a K&T? I wasn’t aware they made shapers. They primarily made horizontal mills. They did make a slotting head for their mills.