Guide: Preparing a block for a Big bore cylinder (part 3)

You need


A grinder


Dremel 565 Multipurpose Cutting Kit



Carbide cutters



picture 01
Original crank diameter is 72mm and Malossi crank diameter is 75.5 mm
So I have to make some room for the larger crank


picture 02
I have made ​​a template with dimensions 76.4 mm (diameter required for the crank is 76.5 mm).
The inner rod has a diameter of 46.5 mm and is the measure bearings has.
Tip
Check figure 8 if you wonder why the template should be less


picture 03
I use the template when I scribes the lines.


picture 04
I use a Dremeln to cut
I have already adjusted the depth to be cut
Tip
A cutter with a flat top is preferred


picture 05
I cut anticlockwise
Tip
I made a block in the middle to easier cut vertical



picture 06
Stay off the line!
NOTE
Beware gasket surface!



picture 07
With sandpaper remove any edge in the bottom



picture 08
Once the template is in the bottom I check with a 0.10 mm feeler gauge for roughness
One half finished


picture 09
The other half i have to cut deeper


picture 10
I scribes contour in the same manner


picture 11
This time i have to do the job in two separate rounds


picture 12
First round


picture 13
Now it's time for some freehand milling
Tip
Take one third at a time


picture 14
Feel with your finger if you got rid of the edge


picture 15
Check the model if it is in place
Once it is in place, you are ready


picture 16
Completed!


picture 17
Original rod about 72mm long
NOTE - I should have measured from the center of the shaft but I was a bit tired...

But you know what I mean .


picture 18
Malossis rod about 80,5 mm long
In other words, Malossis crank is more than 8mm longer than a stock crank!

NOTE - I should have measured from the center of the shaft but I was a bit tired...
But you know what I mean ...

 

this is coming along very nicely.by the looks of things, im surprised it hasnt had any replys