Test Machining of Valve Clearance on Pistons

ok been awhile, sorry about dead images , my google account got disabled so have moved images.

ordered dad a 32mm cutter of fleabay , this was to big to actually fit in is mill , so he modified it , :)

Then he cut a big peice of would at the correct angle for the piston to be mounted to ( to reflect valve angle , yes we think both inlet and exhaust are a little different on angle but not enough to worry)

also we are doing one size cutter for inlet and exhuast valves.

Wood jig at correct angle
close up , see modded cutter

Test cutting went well , valve centres where marked by sending tool down through valve guides on head and marking piston.

now tested on old piston , block and crank need machining now , so new +20 pistons can be fitted ,marked and machined.

Bottom Pulley Keyway

Dad got a spare hour , made a key way for bottom pulley :

1) Milled down to get start of groove square

2) then used mutiple hacksaw blades to form grove

3)Then Used needle files and finished off with a 3/16 square tool steel pressed through

bottom pulley keyway

BMW K1100 Cam Cover mod

ok , next item on list was to cut the end of the cam cover off as this will not fit over cam pulleys , so needs to be cut square so it is flush with back plate ,

mounted square on mill , with cutting blade

Test fitting , just needed another 1m ( or 0.5mm my dad says ) off , ( now done )

another shot

Bottom Seal

As my dad does not have access to allot of equipment , he finds it easier to make smaller parts , so for all the seal locations , he will machine small round seal locators that are they easily aligned to the shaft they are made for ,

see below for example of crank pulley seal. ( also visible is spacer for lower cam pulley

lower crank seal

Cam Adapters / pulleys

Dad started making up some cam adapters , we had picked up some Honda ST1100 motor bike cam pulleys as they seem about the right size and fit

start of cam adapters

Picture below of Honda Cam pulleys in place , and a 3rd one that has been bored out to fit onto mini cam

Honda bottom pulley also bored out to fit over mini crank (no key ways done at this point )