Fenfast Posted November 29, 2009 Report Share Posted November 29, 2009 Here are the first details of my project, breifly mentioned in PB a couple of months back. The planning started when the 'Don't buy it - Build it' approach fueled my imagination. All I knew is I wanted a faster more powerfull Rgv, I wanted to push myself to the limit. I thought a '500' Rgv would be fantastic, but I'd have to make the crankcases - scaled up Suzuki items that would except 250 motocross cranks and top ends. There is so much work involved in that, and I didn't know if the extra power would be worth all that effort, so I took it all the way using CR 500 engine parts to create a 1000. The light weight Rgv frame would simply be phisicly too small for the much larger engine and the fierce vibrations could make it fail anyway, so a larger one was needed. An SP1 would have been great, but I'd need a complete bike and my budget couln't streach to that, An early Aprilia Rsv Mille was purchased and the designing could start. Its a long process full of back peddling and it still isn't finalized in all its detail, but there was enough that I was sure about to make a start. First Challange, getting 2+ tonnes of milling machine down a gravel drive when it realy wants to go to center of the earth! Part of the planning process was a wooden mock up mimicking where the barrels would fit - A CR500 barrel and head in approximate position - The right side of the right engine case being made, showing the top rear engine mount position and two pockets where the gears on the end of the crank will sit. My first design was a single crank just like the Rgv, but the neccesary 100 mm off set would make the engine too wide, twin cranks make the engine 75mm narrower - even then it will only just fit when done. The rough outer profile is a result of 'chain drilling' the shape the right case slowly taking form - a veiw from under the front right side. I'll add further details when there is progress, this is a long term project, so it wont be on the road for a while yet, Hopefully some time in the new year I'll be able to post an update. Link to comment Share on other sites More sharing options...
sennidott Posted November 29, 2009 Report Share Posted November 29, 2009 Now, that is some serious work going on there. Good luck. Link to comment Share on other sites More sharing options...
si.likes.guiness Posted November 29, 2009 Report Share Posted November 29, 2009 very good Link to comment Share on other sites More sharing options...
speedy sie Posted November 29, 2009 Report Share Posted November 29, 2009 fucking owsome,go on.... Link to comment Share on other sites More sharing options...
porter_jamie Posted November 29, 2009 Report Share Posted November 29, 2009 awesome! mate, if you are milling the cases on an old manual mill, then hats off. tell me it has a DRO! out of interest what are you going to do about primary drives to join pot1 and pot2 (gear them together and run one backwards? since i guess the pots will be different ways around?) and what are you doing for a gearbox? I guess the overall ratios of the cr500 box will be a bit short Link to comment Share on other sites More sharing options...
paul g Posted November 29, 2009 Report Share Posted November 29, 2009 Now thats what I call a proper special How you gonna fit the exhausts in? Link to comment Share on other sites More sharing options...
Gary Posted November 29, 2009 Report Share Posted November 29, 2009 One hell of a project, I hope you can take it to completion.. Will be very interesting to see and hear.. Link to comment Share on other sites More sharing options...
laney Posted November 29, 2009 Report Share Posted November 29, 2009 Jesus titty fucking christ,thats one hell of a project.Ive got a cr500 crosser and thats an animal,so the thought of two of the buggers in the same bike scares me!! Link to comment Share on other sites More sharing options...
ricey3 Posted November 29, 2009 Report Share Posted November 29, 2009 holy mother of god! that is what i call awesome! and some big balls needed to mill those cases out, certainly cant do that with a hangover! Link to comment Share on other sites More sharing options...
drunkn munky Posted November 29, 2009 Report Share Posted November 29, 2009 Hats off to that man Link to comment Share on other sites More sharing options...
cagimaha Posted November 29, 2009 Report Share Posted November 29, 2009 1000cc stroker you say? With twin cranks? And home-brewed billet cases? Massive respect to that man. Makes my own attempts at a two stroke special pale in comparison. All I can say is I'll be waiting for the new year update with baited breath! Link to comment Share on other sites More sharing options...
spacemonkey Posted November 29, 2009 Report Share Posted November 29, 2009 1000cc stroker you say? With twin cranks? And home-brewed billet cases? Massive respect to that man. Makes my own attempts at a two stroke special pale in comparison. All I can say is I'll be waiting for the new year update with baited breath! That's a proper project! Hats off! Link to comment Share on other sites More sharing options...
David W Posted November 29, 2009 Report Share Posted November 29, 2009 Good God. I suddenly feel unbelievably inadequate with my standard-bike-with-off-the-shelf-bolt-on-parts! Eleventythousand out of Ten. Link to comment Share on other sites More sharing options...
absinthe Posted November 29, 2009 Report Share Posted November 29, 2009 Great looking project. I can't wait! Link to comment Share on other sites More sharing options...
pepsisteve Posted November 29, 2009 Report Share Posted November 29, 2009 bloody hell! thats one hell of a project you have going on there, good luck with it and look forward to seeing more updates and pics. Link to comment Share on other sites More sharing options...
Rompy McPoot Posted November 29, 2009 Report Share Posted November 29, 2009 Holy shit dude... I'm saluting so much I'm getting RSI in my elbow. Can't wait for more on this. Are you putting a cutout in the tank for your undoubtedly enormous cojones? Link to comment Share on other sites More sharing options...
thesagaciousman Posted November 29, 2009 Report Share Posted November 29, 2009 This is a proper project. Have you done the FEA on the crankcase design? If you used solidworks or something similar you should be able to model the approximate working conditions to see any possible failure modes. Good luck though, this looks like a labour of love. I can't wait to hear it running. Cheers Link to comment Share on other sites More sharing options...
heds954 Posted November 29, 2009 Report Share Posted November 29, 2009 Faaaaaaaaaaarkkinnnnnnheellllllll..... watching with great interest Link to comment Share on other sites More sharing options...
Majik Posted November 29, 2009 Report Share Posted November 29, 2009 Incredible. I'm having to type this one handed. Draw your own conclusions... Link to comment Share on other sites More sharing options...
jayRC3045 Posted November 30, 2009 Report Share Posted November 30, 2009 mate, if you are milling the cases on an old manual mill, then hats off. tell me it has a DRO! what he said , good luck Link to comment Share on other sites More sharing options...
Sidkinky Posted November 30, 2009 Report Share Posted November 30, 2009 Well pinch my cheeks and call me gorgeous. That rocks hard. Link to comment Share on other sites More sharing options...
tootall Posted November 30, 2009 Report Share Posted November 30, 2009 You had me impressed at getting the mill down the gravel drive! As for the rest? Hats off to you mate, the world needs more like you. Link to comment Share on other sites More sharing options...
levo Posted November 30, 2009 Report Share Posted November 30, 2009 Bejasis micheal ..........................that's some top feckin' work there m'boy Link to comment Share on other sites More sharing options...
Jay Posted November 30, 2009 Report Share Posted November 30, 2009 Could I please subscribe to your newsletter? Top top work Link to comment Share on other sites More sharing options...
Superdunc Posted November 30, 2009 Report Share Posted November 30, 2009 Nice Work sir I've been dreaming of build something similar for years. Will be watching this build with intrest. Link to comment Share on other sites More sharing options...
Fenfast Posted November 30, 2009 Author Report Share Posted November 30, 2009 awesome! mate, if you are milling the cases on an old manual mill, then hats off. tell me it has a DRO! out of interest what are you going to do about primary drives to join pot1 and pot2 (gear them together and run one backwards? since i guess the pots will be different ways around?) and what are you doing for a gearbox? I guess the overall ratios of the cr500 box will be a bit short Thanks for your approval - everyone! The mill is donkey's years old but luckily the previous owner had fitted DRO's ('digital read outs' for those not familiar with work shop terms) The 2 cranks both drive a short 'jack shaft' which also has the original mille primary drive on - driving through the clutch/gearbox as standard. The engine will make power at lower revs than the mille so the cranks have larger gears on to keep the gearbox working at what I hope will be about the same speed! Link to comment Share on other sites More sharing options...
gnarly Posted November 30, 2009 Report Share Posted November 30, 2009 As the others said much respect for milling a lump of ally that big manually, and even more to you when you come to kickstart the beast Link to comment Share on other sites More sharing options...
2 smokes 4 ever Posted December 1, 2009 Report Share Posted December 1, 2009 I think I've just cum!! Link to comment Share on other sites More sharing options...
fran9r Posted December 1, 2009 Report Share Posted December 1, 2009 PB need this in the mag... Link to comment Share on other sites More sharing options...
spacemonkey Posted December 1, 2009 Report Share Posted December 1, 2009 PB need this in the mag... HEhe, it would have suited the old PB. 'Buy it, don't build it.' Link to comment Share on other sites More sharing options...
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