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Measuring & Design of FL400 Pilot Cylinder Head Cool
http://www.pilotodyssey.com/PO/viewtopic.php?f=106&t=3891
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Author:  speedchaser [ Mon Jan 14, 2008 10:29 pm ]
Post subject:  Measuring & Design of FL400 Pilot Cylinder Head Cool

Hello drawing up a head for the pilot
2d first
speed

http://pilotodyssey.com/speedchaser.htm

here is the dome 49cc cnc machining

Part 1


Part 2



Thanks For Looking
SpeedChaser

12201-HE0-000 CYLINDER HEAD

Attachments:
File comment: the heads
MVC-454X.JPG
MVC-454X.JPG [ 99.78 KiB | Viewed 9114 times ]
File comment: layout of the stud holes
MVC-456X.JPG
MVC-456X.JPG [ 96.79 KiB | Viewed 9114 times ]
File comment: the over lay print out to see if I got the hole in right spots
MVC-455X.JPG
MVC-455X.JPG [ 90.1 KiB | Viewed 9114 times ]
File comment: the layout of water chambers
MVC-458X.JPG
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File comment: more drawing on the water chambers
MVC-459X.JPG
MVC-459X.JPG [ 104.55 KiB | Viewed 9114 times ]

Author:  speedchaser [ Mon Jan 14, 2008 10:32 pm ]
Post subject: 

the last pic for 2d will start 3d soon

Attachments:
File comment: fished with water chambers
MVC-460X.JPG
MVC-460X.JPG [ 103.22 KiB | Viewed 9112 times ]

Author:  hoser [ Mon Jan 14, 2008 10:48 pm ]
Post subject: 

Is looking good, like that hole spacing Honda invented?

Author:  speedchaser [ Tue Jan 15, 2008 7:06 pm ]
Post subject: 

Look at the water port layout

Attachments:
File comment: Here I put layout die on head and made a imprint on paper
MVC-461X.JPG
MVC-461X.JPG [ 56.25 KiB | Viewed 9061 times ]
File comment: Here I did and over lay from what I have drawn and the imprint
MVC-462X.JPG
MVC-462X.JPG [ 88.67 KiB | Viewed 9061 times ]
File comment: A pic of the light and setup
MVC-463X.JPG
MVC-463X.JPG [ 85.76 KiB | Viewed 9061 times ]
File comment: Drawn o-ring grove around out side
May not use. might go with stock head gasket

MVC-465X.JPG
MVC-465X.JPG [ 115.5 KiB | Viewed 9061 times ]
File comment: Before I go to 3d
MVC-466X.JPG
MVC-466X.JPG [ 113.5 KiB | Viewed 9061 times ]

Author:  speedchaser [ Tue Jan 15, 2008 7:17 pm ]
Post subject: 

Now going 3d

Attachments:
File comment: Here I have extruded the out side profile
And bored two holes in the center

MVC-467X.JPG
MVC-467X.JPG [ 90.56 KiB | Viewed 9060 times ]
File comment: Here I have cut out the water ports
And put all the stud holes in

MVC-468X.JPG
MVC-468X.JPG [ 77.91 KiB | Viewed 9060 times ]
File comment: Here I have cut out hole for socket stud nuts and put hole in center for the dome
MVC-471X.JPG
MVC-471X.JPG [ 85.84 KiB | Viewed 9060 times ]
File comment: Finishing up radius on top
Out side head all done

MVC-472X.JPG
MVC-472X.JPG [ 71.89 KiB | Viewed 9060 times ]

Author:  speedchaser [ Tue Jan 15, 2008 7:34 pm ]
Post subject: 

Now time to work on the center dome

Attachments:
File comment: Here I'm going to make a model
Of the in side of the dome
Filling hole with oil base clay

MVC-473X.JPG
MVC-473X.JPG [ 75.75 KiB | Viewed 9057 times ]
File comment: Here cleaned up clay with knife
so it's all flat and smooth

MVC-474X.JPG
MVC-474X.JPG [ 86.96 KiB | Viewed 9057 times ]
File comment: Here I have waxed up the inside of dome
Nice and thick this is so the bondo doesn’t stick to the dome

MVC-475X.JPG
MVC-475X.JPG [ 101.43 KiB | Viewed 9057 times ]
File comment: A Pic of the Mud
Shrinkage is about .005 per inch

MVC-476X.JPG
MVC-476X.JPG [ 99.15 KiB | Viewed 9057 times ]
File comment: Mixed and pored poke at it too get air bubbles out
Before it hardens

MVC-477X.JPG
MVC-477X.JPG [ 93.49 KiB | Viewed 9057 times ]

Author:  speedchaser [ Tue Jan 15, 2008 7:43 pm ]
Post subject: 

Next

Attachments:
File comment: sand down bondo
then sick in lathe and turn flat

MVC-478X.JPG
MVC-478X.JPG [ 77.94 KiB | Viewed 9054 times ]
File comment: put drill bushing plug hole to
drill a hole thru bondo mold

MVC-480X.JPG
MVC-480X.JPG [ 97.43 KiB | Viewed 9054 times ]
File comment: tapping hole in bondo for mounting
MVC-481X.JPG
MVC-481X.JPG [ 96.32 KiB | Viewed 9054 times ]
File comment: Setup on angel plate and started laying out the dome to find the radius
MVC-484X.JPG
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File comment: one more pic
MVC-485X.JPG
MVC-485X.JPG [ 115.95 KiB | Viewed 9054 times ]

Author:  speedchaser [ Tue Jan 15, 2008 7:52 pm ]
Post subject: 

Drawing the dome profile 2d the in to 3d

Attachments:
File comment: drawing one half of profile
MVC-486X.JPG
MVC-486X.JPG [ 87.38 KiB | Viewed 9051 times ]
File comment: Finished 2d half of dome
MVC-487X.JPG
MVC-487X.JPG [ 84.37 KiB | Viewed 9051 times ]
File comment: Getting ready to revolve the 2d profile in to a 3d solid
MVC-488X.JPG
MVC-488X.JPG [ 74.93 KiB | Viewed 9051 times ]
File comment: 3d dome added plug hole
MVC-492X.JPG
MVC-492X.JPG [ 47.13 KiB | Viewed 9051 times ]
File comment: All done next will be to cut one
in late feb 08

MVC-496X.JPG
MVC-496X.JPG [ 74.11 KiB | Viewed 9051 times ]

Author:  hoser [ Tue Jan 15, 2008 8:01 pm ]
Post subject: 

speedchaser wrote:
Drawing the dome profile 2d the in to 3d


SWEET!

Once again you have out done yourself...

I have the bowl and squish dimensions if it would be easier for you to work with?

Once drawn can you use the cad to cc the volume of the dome?

The squish clearance will need adjusted if we go with using the head gasket, having owned both heads one with O rings and one with the gasket I lean towards using the gasket, the O rings can be a pain in the ass keeping in place while installing, sealing them was not a problem on my engines but I lapped the top of the cylinders before installing to ensure they were flat, if they are not flat and the O ring on the dome sees ANY of the flame it burns up the O ring, the gasket is more forgiving ...

Author:  31kah [ Wed Jan 16, 2008 12:03 am ]
Post subject: 

Very Nice!

Just curious... why do you make a positive of the dome rather than measuring off of it directly?

Author:  speedchaser [ Wed Jan 16, 2008 8:38 am ]
Post subject: 

Hello the reason was that I did want to scribe line in the dome it self
And this is the the old way of doing things
Yes I could of gust put in my cnc mill and use my renshaw probe
But not every body has one.
thank for looking SpeedChaser

Author:  marioparra78 [ Mon Jan 21, 2008 3:25 am ]
Post subject: 

is there a way of machining the dome with a coventional machine. i want to make a head for the fl250 but the only way i could think about maching out a dome is by grinding out a tool with a radias. o i also need to draw up a blueprint for the head.

Author:  31kah [ Tue Jan 22, 2008 1:25 am ]
Post subject: 

You could cut the dome radius on a manual lathe with a radius cutting attachment. It would replace the tool post. All of them that I have seen are typically home made but there are some commercially made units available.

Author:  speedchaser [ Tue Jan 22, 2008 8:10 am ]
Post subject: 

31kah wrote:
You could cut the dome radius on a manual lathe with a radius cutting attachment. It would replace the tool post. All of them that I have seen are typically home made but there are some commercially made units available.


yep that would work
have a look
www.bedair.org/Ball/ball.html

how to make

speed :-)

Author:  marioparra78 [ Thu Jan 24, 2008 12:57 am ]
Post subject: 

Does anybody have a print for water cooled head. I think i could draw up my own. but i would be more comfortable using something that is known to work.I wonder if its worth buying a tool or making a tool. I might be able to borrow a tracer.

Author:  31kah [ Fri Apr 18, 2008 8:20 pm ]
Post subject: 

Speedchaser, did you ever cut any of these? I was thinking of making some, but would rather buy one from you!

Author:  hoser [ Sun Apr 20, 2008 1:14 pm ]
Post subject: 

Any updates?

Author:  afastcar [ Sun Apr 20, 2008 1:22 pm ]
Post subject: 

I would buy one for the backup Engine..........

Author:  shoubadaba [ Sun Apr 20, 2008 3:42 pm ]
Post subject: 

Count me in on one also

Author:  mudbogger [ Sun Apr 20, 2008 4:29 pm ]
Post subject: 

Me too-I would love to see this happen as well

Author:  speedchaser [ Sun Apr 20, 2008 10:13 pm ]
Post subject: 

31kah wrote:
Speedchaser, did you ever cut any of these? I was thinking of making some, but would rather buy one from you!


Hello no as of yet I have not cut one . the time gose so fast around hear lately.

Will have some time to cut the out side of the head late this week .

Will have to get with Hoser on the bowl and squish dimensions.

Will post back soon

Thanks SpeeChaser

Author:  speedchaser [ Thu Apr 24, 2008 12:48 pm ]
Post subject: 

cut some parts today

Attachments:
File comment: stock for 6 heads
MVC-658X.JPG
MVC-658X.JPG [ 93.08 KiB | Viewed 8323 times ]
File comment: first side cut wow
MVC-659X.JPG
MVC-659X.JPG [ 99.2 KiB | Viewed 8323 times ]
File comment: next view of the bottom
note the radius in bottom

MVC-661X.JPG
MVC-661X.JPG [ 92.2 KiB | Viewed 8323 times ]
File comment: fixture for cutting the other side
MVC-663X.JPG
MVC-663X.JPG [ 62.62 KiB | Viewed 8323 times ]
File comment: mounted and ready to cut
MVC-664X.JPG
MVC-664X.JPG [ 61.47 KiB | Viewed 8323 times ]
File comment: it's cut
MVC-665X.JPG
MVC-665X.JPG [ 73.08 KiB | Viewed 8323 times ]

Author:  hoser [ Thu Apr 24, 2008 1:01 pm ]
Post subject: 

Looks great I assume the dome is next? :-)




-::

Author:  speedchaser [ Thu Apr 24, 2008 1:02 pm ]
Post subject: 

with a brush finish

will try to get to the dome this weekend
my have some ready to go out late next week
thanks for looking
:-) Speedchaser :-)

Attachments:
File comment: with a brush finish
MVC-666X.JPG
MVC-666X.JPG [ 79.72 KiB | Viewed 8305 times ]

Author:  hoser [ Thu Apr 24, 2008 1:09 pm ]
Post subject: 

speedchaser wrote:
with a brush finish

will try to get to the dome this weekend
my have some ready to go out late next week
thanks for looking
:-) Speedchaser :-)


Nice..

Can we get them personalized with writing of our choice on top? I would like PilotOdyssey.com on mine :-)

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