obr_technology
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| posted on 3/8/16 at 09:20 PM |
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Hi Ugg,
Like the idea and would have saved me about ten grand!!!
Project is rumbling on, took the crankcase to a couple of machine shops to check the first price I had for line boring and it seems pretty
competitive.
Took it in with the money ready and got a call from them saying they thought it was just the bearing caps which were poorly machined.
I've since measured the caps against my CAD models and there are some serious discrepancies.
I've gone back to the friend who organised the machining for me who is going to see what he can do to, long story but I really should have
checked these a year ago! At the time I got them I was going through a restructure at work so head wasn't really in the project so jumped to the
conclusion that it was the crankcase that was out of line or my CAD models.
Anyway, worst case scenario the shop can still line bore it for me but worth pursuing I think.
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Ugg10
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| posted on 3/8/16 at 09:37 PM |
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Sound like some progress, glad you are getting to the bottom of things.
My thoughts are no where near as elegant or will produce anywhere near the results of your ingenuity. Also they are just thoughts, at least you are
doing something about yours. Maybe when I get the anglia on the road I may look into it further (also got an idea to try and make a CEM engine, google
it, very interesting idea, piston linear rotary combination with very few moving parts).
Did you sort out your idler shaft bearings iirc you were after ones that ran at 26k rpm?
Cheers.
---------------------------------------------------------------
1968 Ford Anglia 105e, 1.7 Zetec SE, Mk2 Escort Workd Cup front end, 5 link rear
Build Blog - http://Anglia1968.weebly.com
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coyoteboy
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| posted on 4/8/16 at 12:56 PM |
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Interesting work. What kind of gearing are you using between cranks that can handle the torque? Do you have harmonic balancing to prevent vibe issues?
What gearbox is going on it?
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obr_technology
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| posted on 4/8/16 at 02:06 PM |
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quote:
Originally posted by Ugg10
Sound like some progress, glad you are getting to the bottom of things.
My thoughts are no where near as elegant or will produce anywhere near the results of your ingenuity. Also they are just thoughts, at least you are
doing something about yours. Maybe when I get the anglia on the road I may look into it further (also got an idea to try and make a CEM engine, google
it, very interesting idea, piston linear rotary combination with very few moving parts).
Did you sort out your idler shaft bearings iirc you were after ones that ran at 26k rpm?
Cheers.
Thanks.
Not had chance yet, I can imagine in the not to distant future I'll end up with a functioning bottom end which will then send me into panic
about assembling the rest! Still thinking about the needle roller bearing though as it seemed to be able to cope with the speed assuming I can get
some form of lubricatoin in place.
How's your anglia coming along?
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Ugg10
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| posted on 4/8/16 at 02:25 PM |
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quote:
Originally posted by obr_technology
How's your anglia coming along?
Nice - functioning bottom end sounds like real progress.
Been a bit slow over the summer due to holidays and family stuff, also had a bit of a mare with the engine.
Engine was running (ish) on a base map, found the front crank seal was leaking so decided to change, easy me thinks. Set to TDC, locked the cams,
wedged the flywheel and undid the crank pulley. Found that the cam and crank pulleys have no keyways. Replaced the seal, put the pulley back on and
then started the engine, couple of turns, fired and then would not run. Crank pulley had slipped, suspected bent valve. Online manual I was using did
not say to replace the crank pulley bolt as it was a stretch one. Put it back together again and runs but not that well. So, rather than sending many
hours tracking down the problem which may or may not end up with a new motor (or head off) I spent £90 on a new engine so that is currently being
stripped down ready for the swap over. Also decided whilst I am at it to install the RX8 6 Speed box just for the fun of it. So about 6 months behind
schedule but most of the rest of the car is ready to go once I have sorted this out.
Any more ideas as to what you are going to put this engine in? I do like the idea of a Spire GTR with an audi transaxle, mini LMP2 car :-)
And are you going to keep the oem electrics for now i.e. run as 2 separate engines linked or have you though more about ECU's to run both
together ?
---------------------------------------------------------------
1968 Ford Anglia 105e, 1.7 Zetec SE, Mk2 Escort Workd Cup front end, 5 link rear
Build Blog - http://Anglia1968.weebly.com
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obr_technology
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| posted on 4/8/16 at 05:25 PM |
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quote:
Originally posted by Ugg10
quote:
Originally posted by obr_technology
How's your anglia coming along?
Nice - functioning bottom end sounds like real progress.
Been a bit slow over the summer due to holidays and family stuff, also had a bit of a mare with the engine.
Engine was running (ish) on a base map, found the front crank seal was leaking so decided to change, easy me thinks. Set to TDC, locked the cams,
wedged the flywheel and undid the crank pulley. Found that the cam and crank pulleys have no keyways. Replaced the seal, put the pulley back on and
then started the engine, couple of turns, fired and then would not run. Crank pulley had slipped, suspected bent valve. Online manual I was using did
not say to replace the crank pulley bolt as it was a stretch one. Put it back together again and runs but not that well. So, rather than sending many
hours tracking down the problem which may or may not end up with a new motor (or head off) I spent £90 on a new engine so that is currently being
stripped down ready for the swap over. Also decided whilst I am at it to install the RX8 6 Speed box just for the fun of it. So about 6 months behind
schedule but most of the rest of the car is ready to go once I have sorted this out.
Any more ideas as to what you are going to put this engine in? I do like the idea of a Spire GTR with an audi transaxle, mini LMP2 car :-)
And are you going to keep the oem electrics for now i.e. run as 2 separate engines linked or have you though more about ECU's to run both
together ?
That's a shame about the seal replacement, it always seems to be the small jobs that end up costing the hours!
Yeah, I'd love to see it in something like that. I'm going to build a frame to run it in to start with, as I think it will be more
interesting to somebody who wants to put it in something if I can get it running first. As money is really tight at the moment I think it'll
probably stay in that frame for sometime, although if I do happen upon some cash I'd certainly be thinking along the radical sr8 type of fitment
so a modified spire or radical would be good.
As you say I'm going to keep it as simple as possible on the ECU front, just using the Kawasaki stuff.
Once I've got some cash I'd like to upgrade to the zx10 or zx14 throttle bodies with a programmable ECU but I think that is a little way
off.
[Edited on 4/8/16 by obr_technology]
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obr_technology
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| posted on 10/2/17 at 09:28 PM |
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Hi All,
Just a quick update to say the project is back in motion...
Ive bought this on Thursday so finally have an oil cooler to put in the big pile of bits!
In the meantime our technician has started programming the bearing carriers into the CNC mill.
I've got a bearing to take in so we can test the hole diameter is going to work, a small from what I can see my 62mm bearing will need a 62.04mm
hole for a 'press fit' but want to check it out on a piece of scrap before machining the nice chunk of 7075 alloy.
Will upload some pics of the machining one finished as well as anything else which I get done.
Cheers
Olly
[Edited on 10/2/17 by obr_technology]
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Ugg10
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| posted on 10/2/17 at 09:52 PM |
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Cool, so you found some bearings that run fast enough for the idler shaft then, great news.
---------------------------------------------------------------
1968 Ford Anglia 105e, 1.7 Zetec SE, Mk2 Escort Workd Cup front end, 5 link rear
Build Blog - http://Anglia1968.weebly.com
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Gre3D
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| posted on 10/2/17 at 10:48 PM |
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nice project, i wish i had your skills 
good luck on finding time to finish this one !
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obr_technology
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| posted on 11/2/17 at 03:35 PM |
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quote:
Originally posted by Ugg10
Cool, so you found some bearings that run fast enough for the idler shaft then, great news.
Yes, had some friends round and was chatting to one of them who is a designer at Dyson.
I was chewing over the project with him and he suggested a type of bearing in I'm not familiar with so I've written the name down for when
I'm ready!
How's your project coming along?
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obr_technology
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| posted on 11/2/17 at 03:37 PM |
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quote:
Originally posted by Gre3D
nice project, i wish i had your skills
good luck on finding time to finish this one !
Thanks, you're too kind!
It all just takes an eternity to do the smallest jobs, but God to be making progress again.
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Ugg10
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| posted on 11/2/17 at 03:45 PM |
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quote:
Originally posted by obr_technology
quote:
Originally posted by Ugg10
Cool, so you found some bearings that run fast enough for the idler shaft then, great news.
Yes, had some friends round and was chatting to one of them who is a designer at Dyson.
I was chewing over the project with him and he suggested a type of bearing in I'm not familiar with so I've written the name down for when
I'm ready!
How's your project coming along?
Bit slow but got the second engine in, rx8 box in and prop shaft on. However, clutch arm is not in the right position so need to pull the box and make
a soaker or extend the arm pivot. Also need to get the engine running better. But I have a deadline for Easter as my garage is being knocked down and
need to move the car so best way is to get it legal which means mot.
There is a guy on the 105speedhyperboards forum putting a tkd bike v8 (Yamaha R1 blocks irk, 380hp) in an aglia, nice project.
---------------------------------------------------------------
1968 Ford Anglia 105e, 1.7 Zetec SE, Mk2 Escort Workd Cup front end, 5 link rear
Build Blog - http://Anglia1968.weebly.com
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obr_technology
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| posted on 11/2/17 at 11:30 PM |
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quote:
Originally posted by Ugg10
quote:
Originally posted by obr_technology
quote:
Originally posted by Ugg10
Cool, so you found some bearings that run fast enough for the idler shaft then, great news.
Yes, had some friends round and was chatting to one of them who is a designer at Dyson.
I was chewing over the project with him and he suggested a type of bearing in I'm not familiar with so I've written the name down for when
I'm ready!
How's your project coming along?
Bit slow but got the second engine in, rx8 box in and prop shaft on. However, clutch arm is not in the right position so need to pull the box and make
a soaker or extend the arm pivot. Also need to get the engine running better. But I have a deadline for Easter as my garage is being knocked down and
need to move the car so best way is to get it legal which means mot.
There is a guy on the 105speedhyperboards forum putting a tkd bike v8 (Yamaha R1 blocks irk, 380hp) in an aglia, nice project.
Good stuff, glad you're making progress.
Would be interested to see the TKD Anglia, is there a page I can see the build on or is it locked to members?
I saw the TKD unit at autosport years ago, I believe it's something to do with the chap who runs the bugatti owners club but sure somebody on
here will be able to correct me!
It's a well proven design with success in hillclimbing so sure it'll work well assuming it's got enough torque to shift the tinwork!
From memory the zx9 had 70NM, so at best I might see 140NM from my engine which is why I have always planned to use it in something as light as
possible.
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Ugg10
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| posted on 11/2/17 at 11:54 PM |
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Here's a link, try this out - http://105speed.hyperboards.com/action/view_topic/topic_id/17236
I think he said that it was used in the back of a pilbeam so hillclimb it was. The Anglia was only 720kg off the ford line so with the iron engine and
box plus interior removed surprisingly it is not much heavier than a seven (well a Larry one with a pinto).
Pictures on here - https://imageshack.com/user/FYB613C
Just to give you an idea of what it looks like
---------------------------------------------------------------
1968 Ford Anglia 105e, 1.7 Zetec SE, Mk2 Escort Workd Cup front end, 5 link rear
Build Blog - http://Anglia1968.weebly.com
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obr_technology
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| posted on 12/2/17 at 09:03 PM |
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Thanks, typically the link was locked to members but some great pics in the second link.
I get what you are saying about the lightweight Anglia, I'd just always imagined these high revving v8's in tubular chassis with composite
panels such as the radical sr8, SHP RSR escort or Palotov D1. In reality it would still be pretty quick in a saloon car not forgetting it needs to
handle and stop!
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obr_technology
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| posted on 16/2/17 at 09:47 PM |
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Machining
Had a great evening with our CNC guy at work.
We wanted to check the bearing fit for some carriers we wanted to mill.
We started with a piece of scrap and used the screen to input the program. As you will see gone are the days of writing lines and lines of code
yourself!:
Here is a pic of setting up the material, using the sensor to set the x, y and z points.
Once programmed and setup the process ran very quickly and we were then able to fit the bearing. We then ran a another cut at 62.04mm which is what my
design table had suggested would provide a press for for this bearing. It was clear that at 62.04mm the bearing was not being sufficiently held so we
will cut the final part at 62.
We the took the bullet of 7075 T6 alloy which I bough about 3 years ago and cut into the required sections for the four bearing carriers, here are
two:
We then loaded up the program which he had done during the day, adjusted the hole size to 62mm and are ready to run the process.
Sadly I got the call to have to head home, so we have stopped but plan to do another night next week.
It was great fun, and CNC programming has come a long way since I last used it.
Thanks
Olly
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obr_technology
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| posted on 18/2/17 at 06:16 PM |
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Also managed to get a quick video of cutting the hole for the test piece:
http://i279.photobucket.com/albums/kk143/hornetob/Engine/th_20170216_174241.mp4
I'm still buzzing from this, feel like we are really rolling again now!
[Edited on 18/2/17 by obr_technology]
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obr_technology
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| posted on 21/2/17 at 08:23 PM |
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I forgot to mention (I think) that some of my students were looking for a project this year so are modelling/simulating fitting a twin turbo system
onto my engine.
They will do the simulation in Ricardo software and have already modelled the various manifolds they presented as concepts.
The image below shows a mock up of the engine fitted to a Hewland transaxle in the college Radial PR6 (not designed for this type of installation so a
bit of a tight squeeze but you get the idea!)
Before somebody asks, no it doesnt have a solid axle but the students wanted to get an idea of where the wheel centreline was!
[Edited on 21/2/17 by obr_technology]
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Ugg10
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| posted on 21/2/17 at 08:58 PM |
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Progress, great and nice little project for the students, axle and box output bosses don't seem to line up though. Would go well in a spire gtr
as a cost effective test platform (race proven).
I now know why you were interested in the cast stainless manifold thread. An m62 supercharger would fit nicely in the v aswell.
So, when are the kit price and delivery slots going to be released :-)
[Edited on 21/2/17 by Ugg10]
---------------------------------------------------------------
1968 Ford Anglia 105e, 1.7 Zetec SE, Mk2 Escort Workd Cup front end, 5 link rear
Build Blog - http://Anglia1968.weebly.com
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obr_technology
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| posted on 21/2/17 at 11:06 PM |
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quote:
Originally posted by Ugg10
Progress, great and nice little project for the students, axle and box output bosses don't seem to line up though. Would go well in a spire gtr
as a cost effective test platform (race proven).
I now know why you were interested in the cast stainless manifold thread. An m62 supercharger would fit nicely in the v aswell.
So, when are the kit price and delivery slots going to be released :-)
[Edited on 21/2/17 by Ugg10]
Thanks, yes it makes sense for them and I'm certainly driving them hard!
Yes the box is just an FTR we had downloaded from the Internet last year so was already in the folder for the moment to use. If we were to use a spire
or a radical like the one in the image we'd need to gain a bit of length between the wheel centreline and bulkhead. Our PR6 is designed for a
hayabusa mounted transversely with a chain diff so very compact. We've also got an SR3 in the workshop which I'd like to measure up as I
don't think it's a lot different to the SR8 which would have been fitted with their own hayabusa v8 and I believe a quaife transaxle.
I was interested in that manifold, sadly the chap didn't have any power curves which I'd have been interested to see the improvement. My
previous project involved making the kit to fit an M45 eaton charger to an old wolseley hornet I had previously restored. It was great fun and I loved
the supercharger whine and torque. I did the same calcs for this engine and believe I'd need the M112 from the jag V8 because the bike engines
Rev so high the airflow is huge.
I've been reading a book about the turbo era of F1 cars having been inspired by my lecturers from Geoff Goddard at uni who was an engine design
god, so really would love to try the twin turbo route if I ever get this project running. You see companies pushing big power from these little bike
engines so I reckon I could get 800hp from my v8 fairly reliably.
Watch this space on the delivery slots, speaking of which we are expecting our 2nd child in August so if I don't get the engine running before
then I'll no doubt have another pause from it....
[Edited on 21/2/17 by obr_technology]
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obr_technology
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| posted on 24/2/17 at 08:39 AM |
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More progress on the mill last night, now have all the fronts for the bearing carriers and just need to spend another evening (hopefully next week)
completing the rears.
Pics and more vids to follow.
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obr_technology
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| posted on 25/2/17 at 10:51 PM |
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Hoping this will work:
[flash=425,350]https://youtu.be/7K5CZAPrdWE[/flash]
[Edited on 25/2/17 by obr_technology]
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obr_technology
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| posted on 25/2/17 at 11:02 PM |
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I give up, this will have to do:
https://youtu.be/7K5CZAPrdWE
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obr_technology
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| posted on 30/3/17 at 08:50 PM |
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Machining Bearing Carriers
We've completed the machining of the bearing carriers now, having done 4.
The surface finish could be better, but the crucial dimensions are within tolerance and that is far more important to me!
We've also had the turbo exhaust manifold 3D printed, which the students have then flow tested on our Superflow bench at work.
[Edited on 30/3/17 by obr_technology]
[Edited on 30/3/17 by obr_technology]
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obr_technology
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| posted on 26/7/17 at 02:47 PM |
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with the loss of photobucket I'm going to just use my Facebook page until I can find an easy replacement, please check it out and maybe even
give it a like to stay updated!:
OBR
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