Badger_McLetcher
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| posted on 18/3/10 at 07:35 PM |
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Flywheels - Probably a stupid question
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
If disfunction is a function, then I must be some kind of genius.
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Paul TigerB6
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| posted on 18/3/10 at 07:38 PM |
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quote:
Originally posted by Badger_McLetcher
Now here's the stupid question - why does no one make their own?
Most people want to keep their legs i guess!! 
I cant see many people would risk it, dont have the facilities to balance it very accurately etc. It'd take a huge amount of effort and so on
even if you did have the facilities to machine and balance it anyway - so whats the point??
[Edited on 18/3/10 by Paul TigerB6]
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MikeR
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| posted on 18/3/10 at 07:40 PM |
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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
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tomprescott
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| posted on 18/3/10 at 07:41 PM |
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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.
A bird in the hand....
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snapper
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| posted on 18/3/10 at 07:43 PM |
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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 eat to survive
I drink to forget
I breath to pi55 my ex wife off (and now my ex partner)
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boggle
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| posted on 18/3/10 at 07:50 PM |
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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........
just because you are a character, doesnt mean you have character....
for all your bespoke parts, ali welding, waterjet, laser, folding, turning, milling, composite work, spraying, anodising and cad drawing....
u2u me for details
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deanwelch
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| posted on 18/3/10 at 07:53 PM |
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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 
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iank
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| posted on 18/3/10 at 07:55 PM |
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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.
--
Never argue with an idiot. They drag you down to their level, then beat you with experience.
Anonymous
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Fred W B
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| posted on 18/3/10 at 07:55 PM |
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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]
You can do it quickly. You can do it cheap. You can do it right. – Pick any two.
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boggle
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| posted on 18/3/10 at 08:03 PM |
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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......
just because you are a character, doesnt mean you have character....
for all your bespoke parts, ali welding, waterjet, laser, folding, turning, milling, composite work, spraying, anodising and cad drawing....
u2u me for details
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liam.mccaffrey
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| posted on 18/3/10 at 08:06 PM |
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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]
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flak monkey
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| posted on 18/3/10 at 08:09 PM |
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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.
Sera
http://www.motosera.com
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mcerd1
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| posted on 18/3/10 at 08:12 PM |
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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  )
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hillbillyracer
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| posted on 18/3/10 at 08:32 PM |
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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.
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clairetoo
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| posted on 18/3/10 at 09:06 PM |
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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 ....................
Its cuz I is blond , innit
Claire xx
Will weld for food......
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mcerd1
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| posted on 18/3/10 at 09:31 PM |
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quote:
Originally posted by clairetoo
I've not had it balanced - I only rev it to around 8000 ...
shouldn't cost much to get ballanced - I got my whole bottom end done (burtons flywheel and cossie crankshaft) for ~£50 I think
one machined out of billet shouldn't be far off, but I'd still rather have it done
[Edited on 19/3/10 by mcerd1]
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Badger_McLetcher
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| posted on 19/3/10 at 01:30 AM |
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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
If disfunction is a function, then I must be some kind of genius.
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bimbleuk
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| posted on 19/3/10 at 06:45 AM |
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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.
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alistairolsen
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| posted on 19/3/10 at 07:40 AM |
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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.
My Build Thread
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