The Making of a 781cc Beast

sfab

X
Location
Canada, QC
Hi folks!
First, id like to introduce my self to you. My name is Jonathan, i live in canada (...) im pretty new to the PWC scene but ive been into the world of mecanics and electronics since im 8. Ive build some nice projects over the years, including go-karts, go-peds, cars, ect... blah blah blah, -insert a couples of ennoying autobiographic lines- .... lol

heres the deal: ive bought a square nose superjet 1995 in 2006 which was in good shape with a couple of nice mods on it. the ski was kinda powerful but did not pack enough "punch". im a fat f*cker (235) so i need something powerful enough to get my out of the water!:biggthumpup:
i decided to build a big bore 61x with some homebrew performance parts that i will design and machine all by myself. ive ordered some BB sleeve for NW Sleeve and a sets of 85.5mm wiseco pistons. i thougth about buying a girdled head from some hi-perf cie but i was tempted to make my own. Took some measurements on my stock head, checked a couple of pics and infos of some girdled heads on the net and came with this design:

760_HEAD_v2.jpg

760_HEAD_2.jpg


i didnt bring the cam to the shop as ive planned so i got no pics of the fabrication but got some nice finished ones:
Image2.jpg

DSCF0608.JPG

Image3.jpg

Image2.jpg


i will try to keep this "log" updated and post pics of the building progress. the next step is to bore the case for the NW sleeves, remove the old sleeves from the cylinder and bore it to the size of the new one. i will also design the domes which is pretty hard to figured out with all the contradictions about squish relief and angle, shape of the combustion chamber... ill try my best to not blow this engine!! LOL i know for sure the compression must be between 170-190lbs.
 
Very cool. Personally, I like the smoother topped heads because they are easier to keep clean. But your's looks pretty sweet.

Why not just buy domes from Pro-Tec or Riva? Seems that engineering is pretty proven.

Aaron
 

sfab

X
Location
Canada, QC
Looks to be an ADA copy with ribs...might as well buy their domes.

that was the original idea but ive screwed up a measure that ive taken on the old ADA head of my friend. i will make a couple of sets of domes that will fit this head with different volumes, ive already figured out the squish relief and angle from the ADA website so i think im good for a try. hopefully it will work great!!:fingersx:
does it worth doin it? hell yes!! only if it works tho...
 

DAG

Yes, my balls tickled from that landing
Location
Charlotte, NC
Very nice, you going to tell us how long that took. Not machine time, but the entire project from concept-sketches-model-r&d-CAMcode-fixtures-machine time.


i got a good 4 months on this dinky turnplate, your head makes my brain hurt...
Looks Great.!!!!:arms: :biggthumpup: :biggthumpup:
 

sfab

X
Location
Canada, QC
Very nice, you going to tell us how long that took. Not machine time, but the entire project from concept-sketches-model-r&d-CAMcode-fixtures-machine time.


i got a good 4 months on this dinky turnplate, your head makes my brain hurt...
Looks Great.!!!!:arms: :biggthumpup: :biggthumpup:

Thnak you very much!! i must admit, from measurements, sketching, 3d model, CAM programming to finished head, about 4 days on and off. ive been doing this for a living (prototyping and complex machining) for almost 6 years, so its no secrets!
 

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sfab

X
Location
Canada, QC
Very nice, you going to tell us how long that took. Not machine time, but the entire project from concept-sketches-model-r&d-CAMcode-fixtures-machine time.


i got a good 4 months on this dinky turnplate, your head makes my brain hurt...
Looks Great.!!!!:arms: :biggthumpup: :biggthumpup:

btw i think your turn plate looks great!! theres difference between designing from scratch (like your turn plate) and me copying existing parts!! :biggrin: lol i will probably try to make something completly new for the girdled head. i got couple ideas and but will probably takes a few weeks, perhaps months to design...
 

DAG

Yes, my balls tickled from that landing
Location
Charlotte, NC
$15 of aluminum? what did you use? did you melt down empty beer cans and mill from a stock cast? damn its more than $15 just to ship.

and 4hr's including programing and machining.. WOW i'd figure machining time itself would take a very min of about 2hr's per side if even that.


cant wait to see how the domes turn out.. just be sure to test compression b4 gassing it up, hopefully its not 80psi or 300:bigeyes:
 

sfab

X
Location
Canada, QC
heres some progress. i have removed the old sleeves by heating it in the oven at max. they came out easily i was surprised, aluminum expand a lot!!
after that, i took the cylinder to the shop to bore it to fit the NW sleeves. i made a jig to clamp the cylinder flat within 0.0005'.
jig.JPG

did the bore to 3.581" +/- 0.0005" (0.005" of interference fit) with a 3.739" dia. counterbore, 0.345" deep. went home, heat the cylinder again and fitted the sleeve in the new bore.
cyl_oven.jpg

sleeve_fitted.JPG

then i went back to the shop, but it right back on the jig and faced the sleeves and deck flush, ive removed maybe a max of 0.005" aluminum off the cylinder.
face_cyl.JPG

i had to bore the sleeves to 85mm minus 0.01" for the honing because it has to bedone at another shop since i dont have the equipement. its a specialized shop that rebuild hi-perf. engine but they had to charge me for the rough cut to bring the sleeves I.D. from 83.3mm to 85mm.... why pay for something i can do?? :D
boring.jpg


heres the finished job:
finish1.JPG

finish2.JPG
 
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sfab

X
Location
Canada, QC
heres the moded case:
mod_case.jpg

its a bit to loose for me but it has the same fit (clearance) than the old sleeve so i think im good to go.
 
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