Matt_E Roundnose Rebuild Thread - Motor Update for 2009

[Matt_E]

Thanks. :biggthumpup:

I'll keep posting the build, but I'll have a couple more weeks downtime, related to my new job, the move, and my parents being in town.

 

[oxnard111]

what's up? anything happen on this build? anything at all besides shuffling it from one spot to another?

 

[Matt_E]

I've been working on it for the past couple of weeks. Usually at least a half or full hour every night.
I've been mostly sanding. Blegh, sanding sucks, it absolutely sucks.
I had to redo my fill-in of the original fuel cap location because when I did it two years ago I used Bondo. Same thing with a couple of other holes in the hull.
I also blended the tubbies to the hull and put the screws back in. Primarily because the tubbies started pulling away from the hull without screws.

I am picking up some closed cell foam soon so that I can start shaping pieces for the tray. I will most likely run expanding foam on the top deck half.
Gotta put all the tubes and exhaust back in, then the tray.

I'll post some pics later today

 

[Matt_E]

Gah, it's 10 degrees outside, so probably 20 in my garage.
I got to do some epoxy work.

 

[oxnard111]

Gah, it's 10 degrees outside, so probably 20 in my garage.
I got to do some epoxy work.

I can't imagine doing it in 20 degree weather... I did in 50 degree a couple weeks ago, and that even sucked.

 

[Matt_E]

Heatgun to make the epoxy liquid, and heat light to cure it.

 

[Matt_E]

Some pics.

 

[Phill]

Are you gonna have that thing done early this year?

 

[Crab]

Are you gonna have that thing done early this year?

Early 09:dance:

 

[Matt_E]

If I didn't have to put up with your slow, sissy driving, I might have time to work on it!

 

[Phill]

Early 09:dance:

:bananalama:

If I didn't have to put up with your slow, sissy driving, I might have time to work on it!

Well that sucked.....not sure what to say about it.

 

[Matt_E]

Pics. Got the drain plugs installed.

Put the one way valve (Blowsion, thanks Chic) in tonight, and started on foam.
Extruded polystyrene.

 

[McDog]

I hope that's not 5200 and ABS on your valve. The 5200 directions say it wont stick to ABS. I figured that out at the last second and went BACK to Lowe's for the 1,000,000th time to get all PVC stuff instead.

 

[thegoldenboy]

Heatgun to make the epoxy liquid, and heat light to cure it.

Buy a heater, you cheap ass....

 

[Matt_E]

I hope that's not 5200 and ABS on your valve. The 5200 directions say it wont stick to ABS. I figured that out at the last second and went BACK to Lowe's for the 1,000,000th time to get all PVC stuff instead.

Not 5200.

A Bostik adhesive.

EDIT: I looked. While certain websites will have you believe that 5200 is incompatible with ABS, 3M's own product datasheet says nothing of the sort. It DOES list ABS in an overlap shear strength table. While it doesn't do as well as other materials, it ranks up there with nylon, PVC, and some metals.

 

[Matt_E]

Buy a heater, you cheap ass....

Too late. It's getting to be 50-ish throughout the day.

 

[thegoldenboy]

Too late. It's getting to be 50-ish throughout the day.

Yeah you're good now...

I run a $50 oil filled heater (Noma), my single car insulated garage stays t shirt weather warm.
Takes 2 hours to reach temperature, maintains it no problem @ 30-50% power. I open the door every hour for 10 seconds or so. I smoke so I like to vent it every so often.

Even on the coldest days (-30 celcius) or - 22F.

I'm in a townhouse so being insulated on all sides but the garage door is key.

Also have 3/4" thick, solid rubber flooring, same mats used in hockey arenas, non porous made of recycled tires. Really warms the body when you're not standing on cold concrete. Cold concrete makes it freezing, and kills the back. Even with good footwear.

 

[Matt_E]

Got some more stuff done. I got the bottom of the tray cavity completely stuffed with closed-cell foam (extruded polystyrene.
This is very solid, hardly any gaps.
Tonight I sealed the big pump inserts (see the four patches of kevlar/carbon).
Then I poured standard 2-part foam on top of it all, to fill in any gaps, and to create a good substrate for putting the tray on.
I'll sand this down soon and get glassing.

 

[Crab]

Looks cool.

 

[DAG]

send pics to yamaha