the airsal kit

ok, as some of you know i have blown my barrel again, so have orderd an airsal and thought i would make a small project for the barrel as people seem more interested now. anywho ive bearly done anything on it as of yet but it should be rolling this weekend hopefully. but back to buissness

the barrel came in good time from scooter attack (as always) but there were a few problems with the kit, some expected some not. the main one was the location of the plug hole in the head (drilled at a strange angle and in the wrong place) you can see it in the pics on scooter centre (should have looked) but not happy and emaild them to see what can be done.



there were a few rough bits on the skirt, obvious casting imperfections that wernt really monitord correctly, so much so that it prevented the piston entering the cylinder smoothly wich is quite worrying really.

the port layout is nice altho they were ALOT less tidy than i was expecting (and i do mean rough shaped ports out the box) the hights wernt TOO bad altho the exhaust port is just a complete mess, not going on anything like that. the entire exhaust tract is misshapen and there isnt much meat in there to open it out altho this can be rectified easily. anyway heres a few pics of the general condition of the kit out the box




as you can see its verry promising but needs alot of work to get it as it should be.
now the fun starts and i started to mark up/infill for the work, the transfer feeds are verry big as std (altho the gasget isnt?!?!?!) so suits a flow'd case. altho mines prity thin so i thought id infill to maximise the seal area (less prone to air leaks obv) also marked out how i want the ports altho not quite as close... have a paper template i drew up but really cant be arsed uploading more pics.. anyway, what was done yesterday about 3 mins after it came out the box







more when i have time as this is tea break tinker time for the min..

 

it is a bit of a pisstake.. ima use a random malossi head with it i think (might take it down a little tho) will compair the pistons an volume's. should be a lil ripper tho thas for sure, that map (if the transfer wasent so close obv) with the right hights/pipe will see easily what an evo can. just lots of work in the exhaust port, and i do mean alot
its almost asif this kit has been made as an off the shelf kit thats detune. wether this is just sloopyness on the manufactor's part or its actually intentional for a certian league of racing (same barrel so the factory team have an advantage of what the barrel was made to run like) but ye, can lay REAL nice maps on them and the transfers can EASILY be widend as the material behind is deeper already then detuned angle wise. wopuld expect a v torquey powerband altho it would be pritty low, especially with the defects in port shape. anyway its gonna rip, an ima blow it up just as quick as the others

 

wait till i have a decent pipe.. when that lil baby go's up 4MM!!!

 

ye thas the idea nibs, altho i removed the first lot and backfilled it with the plastic in place as its prity easy to get to.. its acrylic with a film over it so you can peal it off (nothing will bond to this film prittymuch) wich was handy. so much on atm i dont know when ima get more done but ill probably have a play in my lunch break or somthing (if im not chatting shit on facebook to whatever bit of bored minge is also sat on there comp at work LOL)

 

m8 ive said all along if anyone needs plastic and its lil bits just send me an sae with a quids worth of first class stamps on or sommin... i CANT BE FUCKED writing addresses on things (honestly, we have a sticker machine at work for a reason) so ye, if it means me doing more than putting it in an envelope anb waiting for the postman ima not do it LOL
but ye send me an sae jiffy and ill send it back wiht some placcy... just give me rough dimentions.

chemical metal is pritty strong, strong enough for cases anyway.. this is aryldite steel version.. jb weld is alot stronger and withstands SERIOUS temp's tho.. the kit in the "week away wiht the dremmel" post was an iron 70 wiht about 1mm of actual iron left on the transfer feeds, the rest is built out of jb..., christ the pm sprinter barrel is probably 40% jb weld going by the picsLOL

 

LOL dont know, im doin quite well in the hot bright workshop with air... oh and no hitting your head LMAO

 

ok.. well its in and running (still probs so its back toa stock flywheel and carb one at a time till i find the prob) shame tho as its killed the perfectly good iron kit that was actually moving really well when it wanted to.. anyway
sorted the kit (blueprint and a couple lil bits here an there to just keep it tidy for now, no point spending 10 hours doing a full poirt if its gonna last 5 mins) but ye, exhaust tract is now the correct shape, no lumps, matches the pipe as well as it can for the peice of shit im running (seriously need a good pipe now) but ye, piston... onh my days.. im running a small end bearing thats slightly wider than the normal one's (just a random one i had about, polini iron i think) as the last one went wiht the piston (came out in little bits tbh) but ye, piston didnt fit on the crank, i thought that a little strange, tryd the old bearing cage and it was thinner, now at this point i thought i might have confused the small end bearings but nope, when messuring the gap in the piston from the airsal across to the malossi pistons (got a few of those dead lying about now) i noticed the clkearance was WELL off, long story short ive cut the piston about so the bearing now clears.. bike runs and starts ok (still sparking incorrectly, alsmot sounds lean as fuck but the carb was fine befor so should be fine now? same with both kits again pointing to an electrical failure) anyway, as soon as i approach higher rpm's it misfires, sounds rich, then lean, then rich wich points to a depolarised flywheel (altho its generating electricity and the pickup is fixed) still haveing real trouble geting my head round it so its a case of illiminating possible's till i find the prob, then try figure WHY

anyway once id done a good 5 hours of fuckin about the kit actually gave really good power (hardly ran it tbh) but off the line feels REALLY torwquay and with the port area and timings im gonna throw on it it should be a lil ripper. the transfer feeds equal that of an evo already so even with a maxed case the extra material on the side is SIMPLY a failsafe to aid the thin gasget. the kit out the box is a no no tho, if your savvy wiht a dremmel and dont mind a bit of work its a great kit, can give great power, if you want somthing to bolt in avoid it, if it does fit its not gonna last too long (the piston wouldent even go in the bore befor i removed casting imperfections) more to come, for now im hunting for a couple bits (flywheel needed urgent and a decent pipe is needed badly)