First Build Underway

[whitey]

well my problems seem solved. Pat you will receive an email shortly

Cobra, thats the crankset I was talking about. I was planning on modifying it like CCC has done, but it just isn't worth it for that kind of money.


"What could be better?" IMO nothing haha

 

[whitey]

Today I got the best Birthday present! all my engine parts arrived. I must say that AGK is one of the best businesses I have ever dealt with. Great customer service and prompt shipping. The items arrived in just 8 days! The packing job was also great

 

[itchybird]

AGK is a pretty solid outfit. You'll have fun building out the motor, I know I did.

Look real hard at your mounts, pick up all the key tubes, don't take any shortcuts. I was very surprised at the power of this motor, its very torquey, and is not a little toy motor. Give it the respect it deserves, otherwise it will tear your frame apart.

Have fun! Oh, and make sure you have a good helmet!

 

[whitey]

Thanks itchibird for the heads up on the amount of torque these engines can produce.

I have encountered a problem though. The driveshaft diameter of the engine is too large. So the front pulley of the CVT won't fit. It seems as if all the clones can be a bit different from the real honda. I will have to lathe it down tomorrow. The shaft is a whole mm too large

here is a pic of the goodies that arrived.

 

[cobrafreak]

Wow, 1mm off. That is huge. What brand engine is it? My Harbor Freight 6.5 was within spec in this department.

 

[whitey]

no brand name on it. I looked at the ebay advertisement and it says that it has a 19mm driveshaft. I don't know what happened. I can't return it in the state that it is in. I hope to get lucky tomorrow when I go to school. They use the clone engines for the student's projects. Hopefully I can find a crank with a 19mm driveshaft lying around among the pile of dead engines and parts

 

[cobrafreak]

You could enlarge the hole in the pulley too, right?

 

[whitey]

not exactly. It has the woodruff key cast into it. So if I was to put is in the lathe then that would damage the ridge

 

[cobrafreak]

I was just thinking that at 1mm, all you need to take off is 1/2 of a single mm on the walls of the pulley to make it 1mm larger. 1/2 of a mm off the woodruff key groove isn't a big deal. Still lots of metal left to hold a key that would need to be 1/2 of a mm shorter. The pulley is only a $40 part. Less than a crank. Another way to do it is run the engine and turn down the shaft as it's running. It would prevent you from needing to disassemble the engine.

 

[whitey]

I already had the engine apart when I found out about the shaft problem. Today was very successful in the fact that the pulley now fits on perfectly. I managed to put the crank on the lathe and take off the 1mm

I also encountered another problem. The driveshaft of my engine was also 15mm too short!. I whopping 15mm. I had a look at the online instructions for the CVT and that confirmed my problem. I then lathed down a piece of round bar to 19mm, leaving a small knob on the end for it to slot into the driveshaft. This allowed me to make sure that it would be perfectly straight. I then welded it and lathed down the weld. There was then the problem of not having a key way the length of the shaft, but that's where the school's new milling machine came into play. I then drilled a hole in the middle of the shaft end and tapped it for the CVT bolt. All is perfect now!

Murphy really isn't on my side

 

[brett7777]

heck, what a mish!
Good on you for persevering mate.

 

[halfpint]

Well done that is great work DONETROON is going to have a good man to train all the best Keith

 

[whitey]

haha thanks Keith. I look forward to seeing your hotrod sometime. I will say that I am happy with the completed shaft. It is slightly longer than the standard, but this is better as more of the pulley's wood-ruff key is being powered by the engine. The shaft used to be flush with the first half of the pulley, you can now see how much it protrudes.

Here are some pics

 

[cobrafreak]

Nice work! That will hold well. Remember it is just pulling a belt and the engagement is very smooth. The woodruff key doesn't get a lot of abuse. Bad luck getting an engine with an odd shaft size.

 

[whitey]

I completed the engine today. I tapped and plugged the holes I created when I removed the governor and low oil sensor. I am looking forward to hearing it run. I couldn't help but get a picture of the billet flywheel. This weekend I will get a new wider loop bent to accommodate the engine.

 

[whitey]

I did a little bit of work on the bike today. I welded the filler cap bung on the fuel tank, cut the intake flanges, started making the exhaust and intake manifold. I wanted to get the carb tucked behind the cylinder of the engine as I will be offsetting the engine. I don't want to be constantly clipping the carb as I pedal the bike.

The exhaust is just a single pipe, no muffler. It will sure be loud! I have made a clamp on extended exhaust and muffler for riding around the quiet neighborhood.

 

[motorhedfred]

It's a bit late to mention this, but I think the head from one of these might fit.

Predator 173 cc OHV Vertical Shaft Gas Engine- Certified for All States Except California

If you download the product manual and look at the exploded view on page 23, the head gasket looks very similar. It appears the intake runner is cast into the pushrod channel. This should put the carb on the backside of the engine and the exhaust on the front.

The trick would be finding the head. I have know idea if you could get it through a Harbor Freight store or if there's a Honda equivilant.

MHF

 

[whitey]

I don't think I would bother spending over $20 if all I wanted was the head. Also there aren't any Harbor Freight stores in Australia so the shipping cost would be very very high. Thanks for the thought. I don't know if it would even work

 

[whitey]

great news today. I managed to get a new loop made. I had allot of trouble finding a business with a roller that were willing to do such a small job. I found a guy 30mins drive away who said he would be willing to do it. He asked what it was for, then after me telling him he said he would do the job for free. He also supplied the pipe that I needed bent. I now have enough space for my engine. I will post some pics tomorrow

 

[brett7777]

great news today. I managed to get a new loop made. I had allot of trouble finding a business with a roller that were willing to do such a small job. I found a guy 30mins drive away who said he would be willing to do it. He asked what it was for, then after me telling him he said he would do the job for free. He also supplied the pipe that I needed bent. I now have enough space for my engine. I will post some pics tomorrow

Looking forward to seeing it Whitey.
Great to get it done for free!