Maintenance & Technical > KX500 Original

cylinder cutaway pics

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stewart:
took a cylinder and halfed it then quartered one half,, to show exh, cracking around kips barrel valves they actully lock the valves from rotating caught this one on dyno was down 10 hp,, also wanted all to look at wall thick ness

stewart:
ps helps to port after cut into ...ha ha ,,, insted of open mind for a diffrent view,, i say open cylinder for a diffrent view

BDI:
I have been wanting to do something like that for a while. I would like to figure out how to cut it apart by the casting seams but that would be very diffacult. I have wondered if you used the acid bath that they use to strip the plating for long enough if you could beat it and get it to come apart do to the fact that the acid bath really attacks the seams. I think that is a great idea Stewart you can look at things in a whole new way.

demographic:

--- Quote from: BDI on January 01, 2008, 01:52:25 PM ---I have been wanting to do something like that for a while. I would like to figure out how to cut it apart by the casting seams but that would be very diffacult. I have wondered if you used the acid bath that they use to strip the plating for long enough if you could beat it and get it to come apart do to the fact that the acid bath really attacks the seams. I think that is a great idea Stewart you can look at things in a whole new way.

--- End quote ---

I doubt that would work as its the mold that was two piece but the cylinder is one piece of cast aluminium, those seams are just the lines where the moulds meet so there is no seam through the cylinder wall, what you are seeing is only the flashing where the two molds met.
This article about making a boardtrack racer gives a reasonable idea how its done but its not on anything like as complex a casting...
http://www.flashbackfab.com/pages/excel29.html

BDI:
I have a thorough grasp on metal casting and how it works and I'm sure your right about what i'm talking about not working or I would have allready done it to make molds to cast my own cylinders.For whatever reason when you have a cylinder replated a few times the acid bath that they use to strip the old plating really goes after the seams and you wind up having to weld the seams in the exhaust port and intake because they crack all the way through. It's like there is more porosity in the seems It may have something to do with the casting process. I would assume they are using something like the lost wax mold making process to cast the cylinders.

 P.S. that is a cool site I have wanted to get into metal casting at home for a long time but I'm to lazy to build my own kiln and to buy one Is very expensive but there are lots of sites out their with good info on how to do it at home.

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