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Merry Christmas and Happy New Patterns!

12/25/2011

26 Comments

 
Hi there! Long time, I know! But, time spent with the nose to the sandstone...errr...grindstone. Phew...that was a LOT of tricky nooks and crannies to sand and blend in smoothly. Worked on Christmas eve too...and will keep at it even today, applying finish coats.
Things which caused delays - biggest one was a modification which will allow *left side shift* with the newer 5 speed transmission. I had never seen one of those transmissions up close until I saw Chumma's. Discovered that the left side shift lever is mounted on a shaft that runs through a hole drilled right through the crankcase. This ofcourse needed a new boss to be accurately located and placed right where this drilling would be. Don't ask me how annoying that was and how long it took :-(  Then there was a change in the timing cover for machining reasons, had to completely remove and rethink the bosses for the oil feed banjo bolts. Better now in wood than later in metal.
Some of the features of the new design:
1. V angle is now 59 deg. This was arrived at after considering feedback on the original Musket engine, making it more compact, reducing length and making frame fitment much easier while allowing both 350 and 500 top ends. The original 70deg. angle was tricky to fit in the frame.  The narrower angle looks nicer, though this is a matter of taste.
2. The oil filter is now housed in the timing cover- the smaller and lower of the two holes visible. This needed a lot of relocation of the internals but simplified the oil circuit (the original motor has an external filter housing which needed more plumbing). The larger and upper hole, at the 'peak' of the timing cover is the ignition/points housing, which is now a part of the casting, as opposed to the bolted on housing in the original engine.
3. Cooling fins sculpted onto the timing cover. Just HAD to do this :-) Pretty! The timing cover is much more in keeping with classic air-cooled aesthetics. It is overall a much more sculpted, smoothly radiused form which recalls fondly the beautiful castings from our favorite vintage engines. Took a LONG time!
4. New motor will allow left side shift with the 5 speed gearbox.

All in all, I think this is an improvement. Let's see how it goes.
Forgive the *slight blurriness* of some photos, after so much sanding, my hands are just a bit shaky :-)
Don't miss the very last photo which shows the two complete sets of identical twins :-). Yup, everything had to be done twice over to make a backup pattern. After the disaster last time....

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26 Comments
Al Newland
12/25/2011 11:54:12 am

These new castings look GREAT! I believe the changes you've made will prove to be worth the added effort. This update and pics have been a pleasant Christmas surprise! :-)

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Steve
12/25/2011 09:34:34 pm

Awsome!! I've been waiting so long for these updates! It looks beautiful! Well done!
What are the chances of loosely "Sitting" a couple of top ends on the patterns just to show how it will look as a complete engine? That would be so cool of you.
Thanks for the great update and seasons greetings.

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Aniket
12/27/2011 01:04:22 pm

Hi Steve!
Unfortunately, the 500 jugs won't sit in the patterns- there is extra "meat" in the holes to allow the smaller 350 jugs to fit too- so the cylinder holes are smaller than the 500 bores. I could mock it up with 350 jugs but...the only two sets I have are the ones currently on the Musket...which just went on a chilly but awesome ride yesterday :-)

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steve
12/30/2011 10:24:59 pm

Understood, thanks man.

Steve Pallot
12/25/2011 10:29:15 pm

Hi,I have been looking at this website every day or two watching your progress and it lifts my spirits when something new comes on,This has been worth the wait,I hope you are well and have a healthy and productive 2012 ,My best wishes to you.

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josh
12/26/2011 08:37:46 am

Awesome update! kinda been looking for an old ironbore to start my next project since hearing from you last. I hope everything goes smoother for you in the future. I cant wait to hear and see the new 1000cc run and drive down the road, Good luck!

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C. Pal
12/27/2011 11:24:22 am

So beautiful- wow! Looks so damn awesome! Well done!

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Pramodh
12/27/2011 11:37:36 pm

Sooper

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silvano
12/28/2011 03:26:36 am

left side shift !!
that are really good news ... to have that right side would be a bit messy for me at least .....

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Jesuraj India
12/28/2011 04:43:38 am

greet works and your project update is the real festival for all bullet lovers.

With Best Wishes,

Jesuraj. S

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joseph mcminn link
12/28/2011 10:23:56 am

good to see it takeing shape asto our conversations in the past I'm still interested Joe

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Ignacio catral link
12/28/2011 12:29:47 pm

These are beautiful!!! Amazing craftsmanship. I have a kick start 500cc bullet and i will be eagerly following your project.

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Tom Oil
12/28/2011 03:08:14 pm

Realy exciting Aniket!
Beautiful work, and it's a thrill to follow your progress, you should write a book too after the hard work is done!
Tom Oil

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Josh
12/28/2011 09:08:03 pm

Awesome! It's very good to see the progress. Your work looks amazing, love the cooling fins! Are you doing all the work by hand? That must be a ton of work.. no chance of CNC'ing the parts? The compatibility with left-side shifters is brilliant by the way.. pretty sure that would save someone like me some costly repairs (or even costlier accidents) sooner or late,r haha.. keep up the good work!!

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Matt Law
12/29/2011 12:30:37 am

GREAT WORK!!! I was going to put a Meteor or Interceptor engine in my '99 Bullet frame,but I'll wait for one of these,and gather all of the parts that I'll need...will a standard Albion-type right foot shift gearbox work with this unit,or does it have to be left foot,five speed?

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Chuck
12/30/2011 01:06:38 am

I've also been checking in regularly for an update. And now this. WOW! Anikiet, you've hit it a grand slam with this one. This'll be one of the prettiest engines ever. Best wishes and happy new year!

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Rennjit
12/30/2011 01:52:49 pm

Plain Envious !!!

Its a treat seeing them after the long months. May the God of Thump showers his very best on you, cheers..

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Kay
1/1/2012 07:24:44 am

This IS going to be a beautyfull engine. Changing the cylinder angle to allow 700 ang 1000 cc engines with the same crankcase ist brilliant (and to me also enhances the looks). Lovely detail with the cooling fins, the looks is worth every hour of work you spent. My sincirest congratulations.

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Mr French
1/23/2012 10:34:09 am

Hi Aniket,
Boxes landed on earth, real nice job...
I wish you a happy new year for you and your family. Kiss the baby for me. ciao OM

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bart
1/28/2012 10:21:49 pm

So excited to see this project moving ahead. Remember first seeing the Musket a year or two ago I wishing the builder would go into production. Will be selling my Bonnie for a Musket build.
Thanks....for a beautiful RE retro with some ooomph!

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aniket
2/4/2012 02:19:05 pm

Bart! Don't sell the Bonnie! I have a Musket and a Bonnie and they talk to each other all the time!

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William
2/3/2012 02:16:41 pm

We have a few RE's down here (in New Zealand) which I’m planning on owning one before the end of the year.
I saw your musket a while back and it’s still the best original thing I've ever seen.
Good luck for the rest of 2012.

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aniket
2/4/2012 02:39:27 pm

Hi there William,
Thanks very much and great to hear from NZ! Here's wishing that some of the Bullets over there turn into Muskets. Burt Munro, one of my greatest heroes, might smile upon them :-)

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aniket
2/4/2012 02:43:00 pm

Hi there guys,
Just a quick note to say thanks very much for your encouragement, greatly appreciated as always! To answer some questions:
1. The production castings will be completely CNC machined.
2. This engine will allow either the old 4spd box or the new 5spd box, with either left or right shift...anyway you want it.

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bart
2/6/2012 07:43:16 am

Hi Aniket, do you have any idea of what the final torque and HP numbers might end up as? Ballpark?
Best of luck with the build/project.
Bart

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aniket
2/7/2012 04:04:32 am

Hi Bart,
I haven't dyno'd it but based on the figures for the Bullet singles:
700: 36 BHP @ 5626 RPM, 5.48 kgm at 2875 RPM
1000: 44 BHP @ 5400 RPM, 7 kgm at 3000 RPM
This is with bone stock factory parts and tune, which is rather low.
Higher comp pistons, better carb, jetting, cams etc. can raise the hp figures well into the 50s for the 700 and 70s for the 1000...which will necessitate beefing up of the tranny and brakes :-)

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