Maintenance & Technical > KX500 Original

cylinder cutaway pics

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bigbellybob:
stewart now you need to paint all the different areas with a different color.

demographic:

--- Quote from: BDI on January 02, 2008, 10:09:28 AM ---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 some thing 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.

--- End quote ---

I could well be wrong but I wouldn't be surprised if those areas where theres more porosity are where there had been unfused chaplets to hold the core in place or if the cylinder is cast in two operations the join might be seen from the underside of the transfer ports.
If thats the case one part could be cast first then it acts as a centre for the mold.

You got me thinking now as at first I thought you were talking about the cylinder centreline thats just where the two molds meet but if you were talking about the bit where the transfer port undersides meet the cylinder wall it could be a two pisce operation.

Mmm

stewart:
just for your info this cylinder had been replated ...not by max power though...it has the usaul intake casting bridge flaws   ,, and the breaks in the exh boster ports are the worst i had seen   ,, some one  sold me this on fleebay...o well   ifigure they will have the mojo on them ,,not me i cut it up so no one else  would have problems and to learn from it ..making the best out of somthing bad

BDI:
It would be cool if you could take a cylinder apart by its casting seems because then you could make plaster molds from that then make all the changes you would like to make to the cylinder to the plaster molds then you make all the parts that make up the cylinder from wax. then you assemble the wax parts to make a cylinder then that gets coated with a speicial mold making media that fills all the voids and incases the wax cylinder. Then you fire it in a kiln that hardens the mold and burns out all the wax leaving the empty space of a cylinder. then you fill that space with molten aluminum, once it cools then you can break off the mold and you have a cylinder minus all the machine work and plating. This can be done in your back yard,I have literally seen a video of asian people making street bike wheels in a mud hut next to a rice pattie.

demographic:

--- Quote from: BDI on January 03, 2008, 02:30:48 PM ---It would be cool if you could take a cylinder apart by its casting seems because then you could make plaster molds from that then make all the changes you would like to make to the cylinder to the plaster molds then you make all the parts that make up the cylinder from wax. then you assemble the wax parts to make a cylinder then that gets coated with a speicial mold making media that fills all the voids and incases the wax cylinder. Then you fire it in a kiln that hardens the mold and burns out all the wax leaving the empty space of a cylinder. then you fill that space with molten aluminum, once it cools then you can break off the mold and you have a cylinder minus all the machine work and plating. This can be done in your back yard,I have literally seen a video of asian people making street bike wheels in a mud hut next to a rice pattie.

--- End quote ---
Its quite possible you have already seen this but if not you might find it interesting, regards Scott.

http://www.backyardmetalcasting.com/

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