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What has Dave Been Up To? 29th AUG 2015: 10.66@126.09mph!!

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dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1004013
mactaylor wrote:Hi Dave! Are you going to lighten the big ends?
I am not going to drill them this time,
but narrow them, and the counterweights.
See pics below.

Waiting on a tool holder to cut a 4mm external radius on all the sharp corners.







westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1004014




westi wrote:That's mad Alan.

Doug Sweetman Nil Bastardo Carborundum

2,128 posts · joined Sep 2002 ·

#1004036
Most amazing piece of machining work I have seen. Bravo Dave.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1004471
Next step is to put external radii on the corners.













westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1004472


Then a visit to Crankshaft Engineering to finalise the stroke 91.2mm, (3.590")
and pre-grind the journals to within .004" for nitriding.

Why this stroke? 3000cc, and same barrel length as my current combo.

westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1004473
westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1004474






...and then some oil holes...



westi wrote:That's mad Alan.

dragvw2180 Officially Full-On Dubber

393 posts · joined May 2006 ·

#1004482
Dave thank you for taking the time to let us peek at what and how you do these amazing projects . Mike McCarthy

mactaylor Custom Title Time!

1,005 posts · joined Aug 2007 ·

#1004522
That would be a good blower snout! hint hint!
EVERLAST CONCRETE TANKS
1800 552 123

HappyDaze Superannuated

2,887 posts · joined Jun 2009 ·

#1004536
That thing should be in the National Art Galllery.......not hidden away in an egine, where no-one can see it !
I'd rather wear a Beetle out by racing it than by polishing it!

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1004543




westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1004544
















westi wrote:That's mad Alan.

Stanley I guess the reward is in the doing of it

4,523 posts · joined Mar 2003 ·

#1004585
Hey DB, Did you weigh the original round stock at all to workout how much went into swarf?

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1004601
Snrub on the FW end is extra location to centre the FW.

Did not weight it dude, but it was 162 diameter by 380 long before I started.
I reckon it weighs a quarter of that now.
westi wrote:That's mad Alan.

colin Fahrvergnugen

984 posts · joined Mar 2007 ·

#1004638
That is VW porn.👍👍

Cheers Col

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1004642








westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1004643








westi wrote:That's mad Alan.

modnrod Fahrvergnugen

978 posts · joined Mar 2011 ·

#1004656
I know it's obvious, but you're bloody good at this stuff Dave. 👍

tassupervee That really hurts doesnt it!

1,171 posts · joined Sep 2003 ·

#1004798
*tassupervee salutes*

/Out
Im not a complete idiot, quite a few parts are missing....

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1004919
dangerous wrote:Snrub on the FW end is extra location to centre the FW.

Did not weight it dude, but it was 162 diameter by 380 long before I started.
I reckon it weighs a quarter of that now.
Did some maths and it was over 60kg when I started, and now it is under 12kg.

Balance was 2 grams out on one end,
and under 0.5g on the other.

It is now on the way to Rene's in Adelaide for heat treatment!
westi wrote:That's mad Alan.

Doug Sweetman Nil Bastardo Carborundum

2,128 posts · joined Sep 2002 ·

#1004925
You'll need a Perspex case to show it off.... Too pretty to hide

cnfabo Custom Title Time!

1,353 posts · joined Apr 2008 ·

#1004938
Muffin man,if I was from Tasmania I'd have two hats off for you!!!!!!!!

Legend..

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1005310
Stress relieved:

westi wrote:That's mad Alan.

HappyDaze Superannuated

2,887 posts · joined Jun 2009 ·

#1005314
dangerous wrote:Stress relieved:
You, or the crank Dave ? 😂

Looks nice enough to eat 😎
I'd rather wear a Beetle out by racing it than by polishing it!

mactaylor Custom Title Time!

1,005 posts · joined Aug 2007 ·

#1005328
Hey Dave why not a taper from opposing bigends?
EVERLAST CONCRETE TANKS
1800 552 123

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1005380
I decided to remove as much weight as I could, by step-cutting instead of tapering like my last crank,
without reducing the web thickness next to the bigend-underside,
which is where cracks begin.

This way it is still strong, and has the least 'frontal area' for turbulence and windage,
....I hope.
westi wrote:That's mad Alan.

mactaylor Custom Title Time!

1,005 posts · joined Aug 2007 ·

#1005381
Cool thanx, Always a treat to watch your progress!
EVERLAST CONCRETE TANKS
1800 552 123

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1006569
Not as spectacular now it is back from Het Treatment Services in Adelaide.
Thank you Rene', for getting this done for me before you went on holidays!



Then off to Crankshaft Engineering where Mark came in on his holidays to finish grind the journals.
Mark has been grinding cranks on this machine since 1989, so was able to get the sizes I wanted within .0001".
That is , not one journal was other than what I asked within on TEN THOUSANDTH of and inch!



westi wrote:That's mad Alan.

dangerous 23 Windows of Awesome

5,901 posts · joined Jan 2005 ·

#1006570






Here you can see the difference between a journal that is ground, and one that has been polished afterward.



westi wrote:That's mad Alan.