I've been doing some research into flywheels atm (my project needs a custom flywheel to join the 1uz-fe powerplant to the R154 gearbox) and tbh all they are is a lump of steel or aluminium (balanced to high standards admittedly).
Now here's the stupid question - why does no one make their own?
I can think of several possible reasons (mainly liability) but was wondering if there are legislative reasons against making a custom flywheel (like requiring NDT?). Has anyone considered this?
Stupid question asked, I will now run for cover!
Cheers,
Ben

quote:

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Originally posted by Badger_McLetcher
Now here's the stupid question - why does no one make their own?

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how many lathes in garages have the required gap to turn a flywheel?

Probably the biggest reason combined with liability i'd guess

No such thing as a stupid question imho. I know why I wouldn't make my own, the high precision required to get a balanced one is well beyond my reach.

The problem as I see it is that if its unbalanced it may become unstable and shake the engine/gearbox apart, possibly even cause more damage.

You could make your own pistons and conrods, brake discs and pads.

But you would not know if they were safe or fit for purpose.

i made my own flywheel for my subaru..i also made my own titanium valve spring retainers, inconel valves and billet pistons....

its cheaper to buy in some cases....

would i do it again???

nope........

not a stupid question all you have to do is know your limitations and making your own flywheel is beyond most peoples when thay know what is involved and how much you can buy one for

You could make one, go through the hassle of heat fitting a ring gear, and then send it out to be professionally balanced. A lot less hassle to buy one if you can.

You would also need a very large lathe as said.

I designed and had one made for my project. It's just engineering , and machining.

detail here

Cheers

Fred W B



FLYWHEEL FRONT

[Edited on 18/3/10 by Fred W B]

the ring gear part is fun.......

especially if you are fitting it to ali....

i made my flywheel in two stages...1st a basic billet with a bore, then fitted the ring..then finish turned it, then milled my lightning slots, then sent it for ballencing....cost me £200 ish to make...

my pistons where done on a hass.....for 4 pistons it took me 7 attempts......

I would make one no problem.

My lathe is a gap bed and would easily swing a flywheel.

If I was making one myself I would MPI it at least. Only problem is finding someone with an MPI headstock machine to do it, and a fairly hefty one at that.

Only applicable to steel flywheel obviously

[Edited on 18/3/10 by liam.mccaffrey]

I could if I so desired (19" swing in gap) but when you can normally buy one for £200 thats fully balanced etc its not normally worth the hassle.

Unless of course your choice of engine and box is so weird there is no other way of solving it. Normally the flywheel isnt a problem, you just need to find a clutch to suit.

I bought my steel flywheel, it wasn't worth trying to make one when burtons had one in stock for about the same money

but I got the crank pulley made to my design (my lathe isn't accurate enough )

I can swing about 30" diameter with the gap taken out of my lathe, & I dont consider it all that outsize.
I think the fairly widespread availability of things on the shelf means it just is'nt worth anyone's while unless as said it's something unique.
The likes of Burton & other specilaists will likely get them made in batches at a decent engineering place.

I made my own custom flywheel - as said it is just round bit of ally.............


Ally flywheel / adapter plate

I've not had it balanced - I only rev it to around 8000 ....................

quote:

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Originally posted by clairetoo
I've not had it balanced - I only rev it to around 8000 ...

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Thanks for the replies guys, it's interesting to see that a couple of people have done it and peoples views on it. Much to think about!
Cheers,
Ben

Someone is making the fly wheels and traditionally it was a bloke at a lathe. He just may have a few more years experience and a bigger lathe than you!

Economy of scale and confidence will have a lot to do with most people buying one off the shelf instead.

Id make one happily tbh and I entend to reface the one I have. The balancing issue is taken out in a good build as I'd always have the bottom end balanced afterwards tbh.

As said though, in general for £200 its not worth it.