Alex, if you drill a 0,5 mm hole through one of the piston pin plugs, you do not need to modify the piston for removal of the plugs (3:25 in the video). Just put some compressed air at the hole and the opposite plug will pop out, after which you can push the remaining plug (the one with the 0,5 mm hole) out with a screwdriver through the piston pin.
Some peeps might be frustrated at the lack of progress into getting this motor running right... But... As they say... "Slow and steady wins the race"... So, it's this attention to even the smallest detail that makes it right, and hopefully, this little wonder will give great results! So keep at it Alex, she'll come right in the end!🤞👍 😎🇬🇧
While anxiously awaiting the next iteration of 2STROKE STUFFING...I still can't get over the brute force press-fit technique that Alex used on his cylinder casting and sleeve-especially the crush-damage experienced by the bottom of the aluminum casting, which had to be machined-away to get assembly back to specs. The tremendous stress that has undoubtedly built-up due to this unfortunate procedure-in my opinion-must be at least partially relieved through heat-cycling the assembly in an oven to at least 350 deg F, and then allowed to cool completely; this cycle should be repeated at least five more times, after which any minor (hopefully) deformation of the cylinder can be re-honed back to round...with a recommended taper of perhaps 0.010-inch from the bottom of the sleeve to the bottom of the ports. With such a long connecting rod, the piston side-load on the sleeve will be minimum, allowing for reduced piston/sleeve friction around bdc. Note that the oven-heat-cycling can't be duplicated by simply running the engine through a normal heat-cycling procedure, because the bottom of the sleeve will not come up to an adequate temperature, due to its close proximity with the cool crankcase. Finally...when first run, the engine should again be heat-cycled for benefit of the new aluminum-alloy piston and ring assembly. Same deal-heat cycle for at least six runs. Although I have little hope that any of the above will actually be addressed, at least the critical issue of stress relief is off my chest.
I really appreciate your ability to take a step back and re-look at the work you have already done, find where there might have been errors, and address them. Not everyone has the humility to fix their own mistakes or correct incorrect assumptions - that is as valuable a skill as being able to operate the lathe, or the milling machine. The best tools cannot fix incorrect assumptions. I for one do not mind the pace of the videos - I want to watch you succeed, and I'm willing to see what it actually takes to do so. Keep up the great work.
I remember when you got this mill. It's amazing to me how quickly you have learned machining. I machine pretty much every single day for my business and I feel like your learning curve is exponential compared to mine. Nicely done sir!
Fantastic episode and progress ! I was impressed how you were able to true up those surfaces in the mill after realizing you didn't have a great mandrel for the lathe. Very smart thinking ! 👨🔧
Ahh it kills me when you say you're being slow. I've seen 12 man engineering departments make less progress in a month than you do in 2 weeks, not joking. I hope you do appreciate the immense knowledge you have, and it always feels incomplete sure, but you're doing the work of an entire team, and we're just happy to get a peak at your ideas, even if its not on a TV schedule.
Massive congrats on the 200k mark sir. Nice to see hard work and persistence paying off in that regard, and this yr I can feel you're going to achieve your engine goal 🎉
Watching you is like nothing else on anywhere, its as though every media from my past has tried manufacture what you achieve naturally. I have watched and practiced what you do during the duration of my life time, what you provide Alex is a clear realization of what it takes to be a pioneer engineer.
Nice catch and repair. Hopefully the stressed lower area of the cylinder won't crack after some thermal expansion. With the sleeve putting that much outward force, just adding some more expansion from heating the sleeve may end up splitting the aluminum. Hopefully you have no such issues. We all really want to see you meet your goal with a minimal amount of future issues.
I thought you trying to make a mandrel for that sleeve/cylinder was so neat but at the same time you had to take some material off to make sure it was perfect and of course now it was too small. Brilliant way you solved the challenge though! You eat problems for breakfast, lunch, and dinner. Nice work and very entertaining.
once again we bathe in the fountain of persistence,watching the dogged determination bearing fruit....keep it up alex,it's looking ace buddy.and whoop whoop on reaching 200k!!!!
I am in southern Canada, one week we have -7 to -10c and the next we have 5 to 12c. So I guess I am stuck in the middle. I do miss the consistent jetting weather!
Please talk us how you get degrees from mm piston stroke? It can’t be done by dividing travel by stroke or using a sin function. The math is more complex. So interested how you calculate it.
Have you checked for ignition system latency? You can do a simple check by locking straight timing and free rev with a quality timing light. You might want to use several different timing lights for verification. The extreme RPM your running will be extremely sensitive too even very small amounts of Latency or delay in the ignition system. Congratulations on 2K subscribers!!😊 Cheers my friend!
Wait what? 198 exhaust and 127 transfers? isnt the transfer duration a bit low? blowdown would be 35. i got a moped with 198 exhaust, 136 transfers. blowdown 31. but i hit a rev wall at 11000rpm. my pipe is calculated for 10500. just cant wrap my head around thatyou could get serious rpms from so low transfer durations? Please explain Alex. Usually high reving 2 strokes use something like 204 exhaust and 140 transfer when trying to get a peak at around 14000rpm. Thanks!
Haha my eyechrometer was pretty good the other day setting points I set it by eye and it was perfect. I used to use the points box for setting them but I guess I can just eyeball them now.
Surely, now that the liner and ring are made of the same material (almost) the expansion rate will be better matched than with an aluminium cylinder and an iron ring. I would have thought that would allow you to reduce the ring gap.
I think slightly slower pace makes your project to proceed with more steady steps giving better outcome it think. So IMO no need to rush. I tend to rush I my projects also and one "productive" day makes a mess or mistake that needs a week to clean up.
Like i said inthe last episode, what is the tolerance to press in a sleve in that. With the heat and expansion the cylinder could crack. If you have a bulge in the cylinder its probobly dont feel well? I am not an expert.
You need a 4 jaw chuck for the lathe my man. No skim pass would have been needed. Also, I think an expanding mandrel would have been a good idea, and facing the top face of the cylinder would have been best in the same mandrel on the lathe. That would almost guarantee perpendicularity and parallelism.
Hello from California. I've got a suggestion about your mandrel for your cylinder. Personally, I would have made the mandrel a little longer, and did both ends in the lathe. Then I would be sure if perpendicularity. I like your channel, I just happened across it and subscribed.
I have few questions about your Nikasil videos. I wanted to know what proportions of chemical compounds you used for distilled water: alkaine cleaner, acid Sodium Bisulfate + Sodium Fluoride solution, sodium hydroxide + zink oxide, bath nickel + BN + distilled water proportion, is nickel sulfate (NiSO4) used for bath nickel + BN? and is neutral nickel strike bath NiSO4 + distilled water? what should the pH be for nickel + BN and what pH should be for neutral nickel strike? Can silicon carbide be used instead of boron nitride? what is the maximum grain size? what voltage did you use for neutral nickel and nickel boron nitride plating. I know the current density but I don't know what the voltage is. why did you dip the cylinder in zinc, then in acid and again in zinc? I'm guessing it's some kind of zinc base coating for the next nickel coating, and is it necessary? Isn't just etching in alkaline and acid enough? I'm sorry for the questions, but I don't understand everything by ear, but I understand the subtitles. Could you add subtitles to your videos? I admire you for your knowledge and willingness to share it. Greetings from Poland
Nikasil, What ingredients did you use for the nickel boron nitride bath and what ingredients did you use for the neutral nickel bath and in what proportions to water?
I would love to see this channel make a super upgraded version of the Chinese motorized 2 stroke bicycle kits. It would be cool to see someone make a true 100cc kit with upgraded helical gears and a redesigned ported chainsaw head or something.
I would like to see those engines re-designed from the ground up. Smaller displacement, a freewheel at the rear hub, lighter/lower in the frame, a pull-start and a centrifugal clutch (a two-speed goes against most regulations). Really, I think that they could do better, but I'm not seeing the need for making those bikes faster in the powerband. Rather some added "driveability" factor would be nice, remembering that it's a flimsy bicycle chassis that the power is feeding into, and that the noise factor is a big deal in most locations where these bikes are used.
Fkn hell Me and my girlfriend are driving to Austria from Germany ...900km Drive WE Just switched on fuel Station I was thinking now would be nice to have a new Video from 2 stroke stuffing I click on UA-cam 2 min ago new Video Haha Thank you Jesus
To stop the cross transfer through the piston pin, would it be easier to press an aluminium piece into the centre of the pin so you do not need the plate covers? Seems that the covers can be disturbed easily and might jam in the ports.
YESS the wizard has uploaded! Congratz on 200k subs!
Hell yeah, 200k, well deserved, but also should be 2m+
Agree should be millions more!!
_Slow is smooth, smooth is fast._ Don't rush it. You're doing fine. The new cylinder just is looking great!
Waking up to a Two stroke stuffing video is awesome
Alex, if you drill a 0,5 mm hole through one of the piston pin plugs, you do not need to modify the piston for removal of the plugs (3:25 in the video). Just put some compressed air at the hole and the opposite plug will pop out, after which you can push the remaining plug (the one with the 0,5 mm hole) out with a screwdriver through the piston pin.
Thanks Frits!
Some peeps might be frustrated at the lack of progress into getting this motor running right... But... As they say... "Slow and steady wins the race"... So, it's this attention to even the smallest detail that makes it right, and hopefully, this little wonder will give great results! So keep at it Alex, she'll come right in the end!🤞👍
😎🇬🇧
While anxiously awaiting the next iteration of 2STROKE STUFFING...I still can't get over the brute force press-fit technique that Alex used on his cylinder casting and sleeve-especially the crush-damage experienced by the bottom of the aluminum casting, which had to be machined-away to get assembly back to specs. The tremendous stress that has undoubtedly built-up due to this unfortunate procedure-in my opinion-must be at least partially relieved through heat-cycling the assembly in an oven to at least 350 deg F, and then allowed to cool completely; this cycle should be repeated at least five more times, after which any minor (hopefully) deformation of the cylinder can be re-honed back to round...with a recommended taper of perhaps 0.010-inch from the bottom of the sleeve to the bottom of the ports. With such a long connecting rod, the piston side-load on the sleeve will be minimum, allowing for reduced piston/sleeve friction around bdc. Note that the oven-heat-cycling can't be duplicated by simply running the engine through a normal heat-cycling procedure, because the bottom of the sleeve will not come up to an adequate temperature, due to its close proximity with the cool crankcase. Finally...when first run, the engine should again be heat-cycled for benefit of the new aluminum-alloy piston and ring assembly. Same deal-heat cycle for at least six runs. Although I have little hope that any of the above will actually be addressed, at least the critical issue of stress relief is off my chest.
The shim work on the mill as a plan b to the lathe was really satisfying when it all worked out.
3:00 I tested it in owen. Heating did not chaged gap significantly. One repair manual gave 0.05 - 0.2 mm gap.
Oh that is important so my like and a comment so the algorithm shows it
An oven will give even heating. In actual use the piston and ring will heat up faster than the cylinder and get hotter than it.
@@Surestick88 Why repair manul says 0.05 mm is enough? I bought piston and its ring gap is 0.2 mm
@@Surestick88 All hail the algorithm!
i think he meant that the ring gap gets 0.05 - 0.2 smaller when heated@@jarikinnunen1718
I really appreciate your ability to take a step back and re-look at the work you have already done, find where there might have been errors, and address them. Not everyone has the humility to fix their own mistakes or correct incorrect assumptions - that is as valuable a skill as being able to operate the lathe, or the milling machine. The best tools cannot fix incorrect assumptions. I for one do not mind the pace of the videos - I want to watch you succeed, and I'm willing to see what it actually takes to do so. Keep up the great work.
Loved the jazz in the beginning! Congratulations on 200k
This has got to be the best viewing in youtube history.
I'm totally invested in the attempt.
My favorite channel!
I remember when you got this mill. It's amazing to me how quickly you have learned machining. I machine pretty much every single day for my business and I feel like your learning curve is exponential compared to mine. Nicely done sir!
My eye-crometer. Classic. Love it.
Still get the most excited for your videos. Congratz on 200k.
Fantastic episode and progress ! I was impressed how you were able to true up those surfaces in the mill after realizing you didn't have a great mandrel for the lathe. Very smart thinking ! 👨🔧
What you are doing is so amazing! Talented! Enjoy all the videos!
Ahh it kills me when you say you're being slow. I've seen 12 man engineering departments make less progress in a month than you do in 2 weeks, not joking.
I hope you do appreciate the immense knowledge you have, and it always feels incomplete sure, but you're doing the work of an entire team, and we're just happy to get a peak at your ideas, even if its not on a TV schedule.
Massive congrats on the 200k mark sir. Nice to see hard work and persistence paying off in that regard, and this yr I can feel you're going to achieve your engine goal 🎉
Love the videos!
I go through phases on what I watch on UA-cam but, your channel always keep my interest.
Thanks for the awesome content!
Watching you is like nothing else on anywhere, its as though every media from my past has tried manufacture what you achieve naturally. I have watched and practiced what you do during the duration of my life time, what you provide Alex is a clear realization of what it takes to be a pioneer engineer.
It's really great to see you finding all the little bugs!
15:10 " my eyecrometer is correct " I'm adding that to my book of stock engineers sayings 🙃
great job with the progress on recovering from your engine failure
Nice catch and repair. Hopefully the stressed lower area of the cylinder won't crack after some thermal expansion. With the sleeve putting that much outward force, just adding some more expansion from heating the sleeve may end up splitting the aluminum. Hopefully you have no such issues. We all really want to see you meet your goal with a minimal amount of future issues.
That doesn't matter it's a prototype the barrel will end up thin wall plated
The coefficient of expansion is less, for the iron sleeve, and, as such, won’t increase pressure against the cylinder due to heating
I thought you trying to make a mandrel for that sleeve/cylinder was so neat but at the same time you had to take some material off to make sure it was perfect and of course now it was too small. Brilliant way you solved the challenge though! You eat problems for breakfast, lunch, and dinner. Nice work and very entertaining.
Besides the suspense of the one-off machining and mindboggling calculations, the camerawork is outstanding. 👍
dont rush it, the careful approach will definetly be rewarding in the end
Measuring everything and blueprinting it can only help with outright power and longevity - great job
Slow but sure win’s the race, another great video and it looks from here like you’re loving it all again so that’s fantastic to see.
Here is a great quote from a manufacturing book i read "You can only make as well as you can measure". Love that quote
👍👍👍👍 Awesome comeback on the cylinder flatness issue, that was an awesome solution.
once again we bathe in the fountain of persistence,watching the dogged determination bearing fruit....keep it up alex,it's looking ace buddy.and whoop whoop on reaching 200k!!!!
Perth Western Australia - nearly opposite end of the earth - experiencing massive heat wave - 42°C plus day after day.
I am in southern Canada, one week we have -7 to -10c and the next we have 5 to 12c. So I guess I am stuck in the middle. I do miss the consistent jetting weather!
Just commenting to feed the algorithm Alex. Best Wishes to everyone.
Please talk us how you get degrees from mm piston stroke?
It can’t be done by dividing travel by stroke or using a sin function. The math is more complex.
So interested how you calculate it.
🎉🎉🎉
Amazing achievement Alex 200k subscribers. About time 😊
Have you checked for ignition system latency?
You can do a simple check by locking straight timing and free rev with a quality timing light. You might want to use several different timing lights for verification. The extreme RPM your running will be extremely sensitive too even very small amounts of Latency or delay in the ignition system.
Congratulations on 2K subscribers!!😊
Cheers my friend!
Nice progress, can't wait to hear this thing roar!
I Joe it was a while ago:
Thank you for changing the frame of the videos.!!
Now i can watch in full screen ^^
Wait what? 198 exhaust and 127 transfers? isnt the transfer duration a bit low? blowdown would be 35. i got a moped with 198 exhaust, 136 transfers. blowdown 31. but i hit a rev wall at 11000rpm. my pipe is calculated for 10500. just cant wrap my head around thatyou could get serious rpms from so low transfer durations? Please explain Alex. Usually high reving 2 strokes use something like 204 exhaust and 140 transfer when trying to get a peak at around 14000rpm. Thanks!
change your ignition
Yea port timing around he mentions at the end of the video
ex 198.5
in 128-130
blowdown 34.25-35.25
Lower your compression, change your ignition curve, and get a decent pipe with those timings 👍
My yz250 is under 200deg and mid 30 tranz stock pipe 11500rpm
We believe in you. Don’t stop keep going.
I am curious why you didn't heat the cylinder and/or cool the liner before pressing it in?
Haha my eyechrometer was pretty good the other day setting points I set it by eye and it was perfect. I used to use the points box for setting them but I guess I can just eyeball them now.
Surely, now that the liner and ring are made of the same material (almost) the expansion rate will be better matched than with an aluminium cylinder and an iron ring. I would have thought that would allow you to reduce the ring gap.
I think that the heating of the ring will out-pace the heating of the cylinder liner, such that an iron liner may require a ring gap.
Hey up mate good work keep it going, really looking forward to seeing this version running
As always, amazing work! 👍🏼 Can't wait for the next wideo!
Great work, great video as always. Cheers from Montreal Canada
I think slightly slower pace makes your project to proceed with more steady steps giving better outcome it think. So IMO no need to rush. I tend to rush I my projects also and one "productive" day makes a mess or mistake that needs a week to clean up.
yooooo 200k! congratulations! my favorite norwegian 😉
Hope you didn’t forget the base gasket when last measuring the timing & adjusting the squish?!
Who cares at what pace they come Alax, it's the quality that counts and yours always have that, top quality at that! 👍😁
Like i said inthe last episode, what is the tolerance to press in a sleve in that. With the heat and expansion the cylinder could crack. If you have a bulge in the cylinder its probobly dont feel well? I am not an expert.
You need a 4 jaw chuck for the lathe my man. No skim pass would have been needed.
Also, I think an expanding mandrel would have been a good idea, and facing the top face of the cylinder would have been best in the same mandrel on the lathe. That would almost guarantee perpendicularity and parallelism.
It's always amazing to see machining this enginee by all the ways, Go Alex Go🤜🛠🤛
We're not dissapointed, nor are we in a hurry. Take your time, enjoy the ride and keep at it!
Congratulations on 200k
Hello from California. I've got a suggestion about your mandrel for your cylinder. Personally, I would have made the mandrel a little longer, and did both ends in the lathe. Then I would be sure if perpendicularity. I like your channel, I just happened across it and subscribed.
I have few questions about your Nikasil videos.
I wanted to know what proportions of chemical compounds you used for distilled water: alkaine cleaner, acid Sodium Bisulfate + Sodium Fluoride solution, sodium hydroxide + zink oxide, bath nickel + BN + distilled water proportion, is nickel sulfate (NiSO4) used for bath nickel + BN? and is neutral nickel strike bath NiSO4 + distilled water? what should the pH be for nickel + BN and what pH should be for neutral nickel strike? Can silicon carbide be used instead of boron nitride? what is the maximum grain size? what voltage did you use for neutral nickel and nickel boron nitride plating. I know the current density but I don't know what the voltage is. why did you dip the cylinder in zinc, then in acid and again in zinc? I'm guessing it's some kind of zinc base coating for the next nickel coating, and is it necessary? Isn't just etching in alkaline and acid enough? I'm sorry for the questions, but I don't understand everything by ear, but I understand the subtitles. Could you add subtitles to your videos? I admire you for your knowledge and willingness to share it. Greetings from Poland
Would a simple system to have a variable volume crankcase have any benefit on broadening the power band or just helping idle?
Things are getting exciting now!
I wanna to see the characteristics of power the engine! You are amazing person with unique talents!
Congratulations for your 200k 🎉
Back in the groove, good luck.
Nothing beats coffee and two stroke engine
You forgot the smell of the use of castor bean oil , and methane ( Blenzol ) for 2 cycle engines.
Slow and steady wins the race.
Highlight of my week!!! ❤
The tool you need the most is the one you can never find after watching this video I’m going to spend the rest of the day looking for my 10 mm socket
Nikasil,
What ingredients did you use for the nickel boron nitride bath and what ingredients did you use for the neutral nickel bath and in what proportions to water?
Another video, what a great way to start a weekend 😀
Is the piston for use in cast-iron or nikasil ? There is difference , For cast-iron is bigger tolerance, top diameter is smaller.
Time and effort is gonna bring you places man
Can't wait for the next wideo!
A WIZARD IS NEVER LATE!! THE 2 STROKE WIZARD IS BACK
Oh shit 200k! Fantastic
The best option is to heat up the cylinder and freeze the liner,
It would virtually drop in without any stress to the cylinder.
That flat squish band could give you a hard time later. Also did you remachine the head volume too? A proper toroidal head could give some benefits.
9:20 known as "PIP pop" and 16:45 "lil PIP pop" and 17:15 x3
still an amazing week of progress!
Changed all your port timing now didn't you by milling the base? Hopefully she rips buddy!
Thank you! Awesome video 100%
200k subs wuuw. Congrats :D
Bra jobbat, Well done 🇸🇪🇸🇪🇸🇪
Fuck yeah! Another thing fixed! LETS GOOOO!!!!!
Always good stuff 👍
I would love to see this channel make a super upgraded version of the Chinese motorized 2 stroke bicycle kits. It would be cool to see someone make a true 100cc kit with upgraded helical gears and a redesigned ported chainsaw head or something.
I would like to see those engines re-designed from the ground up. Smaller displacement, a freewheel at the rear hub, lighter/lower in the frame, a pull-start and a centrifugal clutch (a two-speed goes against most regulations).
Really, I think that they could do better, but I'm not seeing the need for making those bikes faster in the powerband. Rather some added "driveability" factor would be nice, remembering that it's a flimsy bicycle chassis that the power is feeding into, and that the noise factor is a big deal in most locations where these bikes are used.
Love your videos, keep it up
Fkn hell
Me and my girlfriend are driving to Austria from Germany ...900km Drive
WE Just switched on fuel Station
I was thinking now would be nice to have a new Video from 2 stroke stuffing
I click on UA-cam
2 min ago new Video
Haha
Thank you Jesus
His name is Alex, not Jesus 😂
Yay 🎉 a new one
Things are looking better Alex! Great job. What was blowdown percentage you ended up with?
bowdown 35.5
@@henkcox8212 Thanks
The master of all mini 2 strokes The stuffins Glad to see you back! The raccoon said hi from Kentucky!
Woot woot…! ❤🐈
To stop the cross transfer through the piston pin, would it be easier to press an aluminium piece into the centre of the pin so you do not need the plate covers? Seems that the covers can be disturbed easily and might jam in the ports.
the plate-covers are from Frits Overmars his FOS cilinder.
Can you remember the Mark Atkinson screw together piston with no wrist pin hole.
I can understand the reasoning for that now!
Good video. Good luck.
Wouldn't it be amazing if you and ASoftaaja made a collab video? Or at least you should definitely meet eachother!
" My eye crometer " 😂😂😂
Has anybody seen the movie groundhog day where is Phil
hey mate do you think il get any advantage to using needle roller in my little end crf250r 2008
headvolume 3,4 CC --- corrected ratio -- 8,3-1
I'm used to the old Intro, so i know where the sound may come from :D