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Thread: New Engine coming - Not been this excited since getting my hand in Amandas knickers

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    New Engine coming - Not been this excited since getting my hand in Amandas knickers

    So my asthmatic low compression TC is now torn apart in Uncle Alex's shed full of heads in the far flung reaches of darkest Lincolnshire, where it appears to rain a lot, and will hopefully emerge shortly with Ussain Bolt-like lungs and a new lease of more energetic life, all be it hidden sleeper style.

    Can't believe how excited I am about this. Dont get me wrong i remember being excited about buying all of my Harleys, especially the first but nothing like this. In fact last time i can remember this level of anticipation and being this excited was in June 1980 and the expectation that all my teenage cunning and planning and courting was going to result in the first venture into the knickers of a a young lady called Amanda (in fact the first venture into anyones knickers if truth be told).
    Of course I had planned well, wanting to reduce the chance of failure by homing in on Amanda who half the town had already successfully homed in on before me...and whilst the risk of contracting crabs was perhaps higher than the national average, it had to be done and was a risk worth taking
    What would the pinion run out be (want to fit gear driven cams) = how long do you play with tits before heading south
    Would the tensioners have disintegrated in their 19 years of abuse in the Dubai heat = how do you undo a bra like a pro
    and so on
    I feel sorry for kids today who can just switch on their iPads and google porn to find out how to do it, though i do worry that today's teenagers may think that all women loved to be choked and pissed on.

    In much the same way that young adults no longer need to save for years to buy a Harley given that you can just walk in and get an easy PCP/finance rather than saving for years, they miss out on that major part of the enjoyment that came from the anticipation and future gratification

    I go to bed thinking of this engine and waking up thinking some more. This day has been well over a year in the making.

    There is no strip down and re-paint of the rest of the bike ever going to happen. Its paint, chipped and bleached out as it is, will be allowed to continue to weather as a mark of respect to it surviving 19 years on the mad roads of the Middle East in the hideous heat.

    Though other bikes may join it in the garage if I ever get a job back in England and even though i started out as not loving these new fangled TC engines; I cannot imagine any future excitement ever getting close to how I feel at the moment.
    Dearest Amanda, you have held the anticipation and excitement trophy for the last 39 years, it was awesome getting in your knickers and I hope it was the best 3 minutes of your life as well, but its time to hand that mantle over to an engine build.

    Work your magic Alex

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    Re: New Engine coming - Not been this excited since getting my hand in Amandas knicke

    Brilliant. Well done Amanda. Now it's Alex's turn to stoke the fires of your desire and keep you smiling for years to come. Let us know what level of orgasm you achieve with the end result.

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    Re: New Engine coming - Not been this excited since getting my hand in Amandas knicke

    Make sure you have good lubricants before getting your leg over.
    Don't get too excited as you may loose concentration and it could all be over in minutes. Take it nice and steady and she will respond perfectly giving you a big smile on your face.
    Last but not least wear protection to be on the safe side because there are some people out there that like buggering around.
    wine [there is the] truth"



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    Re: New Engine coming - Not been this excited since getting my hand in Amandas knicke

    Quote Originally Posted by seanofmacc View Post
    Work your magic Alex
    I'm getting there - here are a few teasers ...

    Cylinders bored and honed in torque plates to match the new pistons ...

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    Stock exhaust port ...

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    Same port shortly after meeting my grinder ...

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    Finished port for now ...

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    Exhaust seat profile ...

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    Stock intake port - non concentric to the manifold as usual ...

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    Roughing out the bowl area ...

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    Finished for now ...

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    Another view ...

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    Intake seat profile ...

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    Compression release valves fitted ...

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    Flow bench testing tomorrow. Both intake ports and both exhaust ports need to flow the same at any given valve lift ...

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    Re: New Engine coming - Not been this excited since getting my hand in Amandas knicke

    That's better than the porn currently doing the rounds anyway Alex - where's me tissues?

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    Re: New Engine coming - Not been this excited since getting my hand in Amandas knicke

    This is what I've been looking at for most of the afternoon. The flow bench very basically is a machine that sucks or blows air through the cylinder head. It sucks through the intake port and blows through the exhaust port and the air flow can be measured in terms of the volume in cubic feet per minute and the speed through the ports in feet per second at multiple valve positions. The trick is to get the right balance of both by playing with the port shape, port dimensions, valve shape, valve angles and seat angles. Flow testing is a time consuming process as multiple trips are often required between the flow bench and the workshop to make small changes to any or all of the aforementioned factors ...

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    The results can be seen on the flow chart which has a vertical and a horizontal axis. The vertical one is the volume of gas passing through the port and you can see that the scale goes from 0 up to 160. The horizontal axis shows the distance that the valve has been depressed from it's closed position when it is touching the seat - known as valve lift. On this chart the valve lift goes from 0 up to 0.600". I take readings at every 0.05" of valve lift. The blue trace is the intake port and the red one is the exhaust port. You can see that the air flow increases dramatically from zero up until about 0.4" of lift on the intake port. This is the point at which the trace usually flat lines on a stock head - the stock valve and port just can't flow any more air after this point. On this chart you'll see that the air flow continues to increase right up to and beyond 0.550" of lift where the rate of increase slows down. A bigger port and bigger valve would have allowed a higher flow rate but at the expense of velocity which would have resulted in more horse power but less torque. Sean doesn't want high RPM power so with that in mind the ports and valves are set up accordingly ...

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    Here's the flow numbers in table form which is easier to see than the graph. Looking from the left you'll see the 'lift' column second one in then the 'CFM' column on the far right. See how the port takes a big gulp of air as the valve passes from 0 lift up to about 0.400" where it starts to slow down. The smallest increase is between 0.550" and 0.600" so this tells me that these heads will work well with any cam profile up to about 0.550" of lift. Anything below that is wasting air flow capability and anything above is wasting valve lift ...

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    The early TC heads (1999-2004) have double valve springs in them which limit the cam choice to about 0.510" of lift. This is the point at which the coils are in danger of binding. This is usually not a problem as the stock 99-06 cams have only 0.473" of lift. Now that our heads can support a bigger cam we need to change the valve springs to the later single beehive springs that came as stock in the later 2005 onwards heads. These springs can handle up to about 0.600" lift and come with the added bonus of a much lighter top retainer which weighs only 11 grams compared to 25 grams for the earlier one. This means less mass so less inertia in the valvetrain which means faster acceleration ...

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    The heads are finished now and I've cut the combustion chambers to 86cc which ties in with the cam and piston choice.

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    Hopefully get the rings gapped, pistons fitted and cam chest back together tomorrow ...

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    Re: New Engine coming - Not been this excited since getting my hand in Amandas knicke

    One of the heads can be seen here assembled with the springs that I mentioned before. These springs come as stock on the later 2005 onwards heads with 7mm stem diameter valves. Ours have special conversion hardware which allows the later springs to be used with the earlier 5/16" stem valves.

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    Based on the results from the flow bench I decided to use the Andrews TW54 cams. They have a valve lift specification of 0.555" so they match perfectly what the heads can flow. They have an intake valve closing point of 42 degrees after bottom dead centre which should put the peak torque just where Sean wants it. Here are the cam chest ingredients - nothing but the best going in here.

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    I had measured the pinion shaft run out earlier at less than 0.0005" which is the best stock crank I've ever come across. I still maintain that the 2000-2002 years produced the best Twin Cam engines ever made. This is what allowed the use of the gear driven cams - no more tensioner pads to think about - ever. Here's the cam chest back together with the drive gears in place.

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    These are the pistons I decided on - they are SE cast pistons with a 11cc dome. In the last post I mentioned that I'd cut the combustion chambers to 86cc. The dome volume, chamber volume and the appropriate head gasket will give us 10.26:1 static compression. That compression ratio combined with the intake closing spec of the cams gives us 195psi cranking pressure - perfect.

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    With that cranking pressure the ignition timing curves need to be retarded to get the best results. That is taken care of with the adjustable ignition unit shown here. Accurate timing is a critical factor in engine performance but is often overlooked.

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    That's my bit nearly done as the engine is now halfway through the heat cycling procedures. Tomorrow I'm hoping to get out on it and break the rings in then it will be handed over to Sean to put it through it's paces. If anyone has any questions just contact me on here or email. Thanks for reading!

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    Re: New Engine coming - Not been this excited since getting my hand in Amandas knicke

    Thanks Alex, can't wait to get her back. That cam chest is just gorgeous, almost a shame to cover it up.

    I am going to enjoy growing old (one day) with this old bike and its new, almost stock looking motor.

    Thanks for translating my mindless drivel on what I wanted from this build into hard mechanical parts that will gel together.

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