Husqvarna supercharged 418 build

[BoxerOtto]

well, here it is finally. it works and seems to be reliable enough and its very fun to ride." miles with smiles " right. the building was fun and challenging but the riding is way funner.

[BoxerOtto]

tool box

pouring aluminium

418 engine amr 300 1 to 1

[Tetronator]

Nice bike you've got there.
What gearbox did you use?

[BoxerOtto]

1982 kawasaki kdx 175 engine. crank removed,strait shaft instead.

[Tetronator]

Nicely done... Explains why I didn't recognize it.
But is that little 175cc's transmission and clutch strong enough for your diesel in the long run?

[BoxerOtto]

well the bike has about 6000 km total recorded on speedometer and about 1000 to 1500 unrecorded before speedometer riden hard in the dirt and this passed off season i dissmanteled the complete trans to inspect and there were no signs of trauma so i'm going to keep running it.

[Tetronator]

Sweet, guess they don't make 'em like they used too.

[bf109v7]

Very well done! Respect! Did you lower the compression ratio of the enginge? And how much bost do you run?
Alex

[BoxerOtto]

yes i lowered the comp ratio to 17 to 1. idling boost is about 5psi 3600 to 3800 rpm is about 10 to 12 psi. 3200km's used 77l of fuel.

[bf109v7]

Do you think this gearbox would take a Diesel?
.olx.ph/index.php/view+classifieds/id/70662252/Kawasaki+125cc+with+side+car?referralKeywords=kawasaki+2+stroke
Bigger 2 Strokes ara very rare in the Phillipines.
Alex

[BoxerOtto]

not sure. without seeing it opened up its hard to say.you will need some engineering and machining capabilities to make it happen regardless which trans you choose.

[mark_in_manchester]

Nice foundry work - is that your plenum 'ends', and did you cast them directly into the tube they were designed to fit into?!

I've not cast anything bike-related yet in my setup - except for a Norton sidevalve tappet cover I did because I had one with holes in which someone had screwed to my mate's garage wall. I filled the holes with epoxy putty and used it for a pattern - it's my first 2-sided effort and came out well. I'd sell them for a lots of money, but unfortunately, for obvious reasons, it's a bit small

Recently I found a whole pile of rolls of ceramic-wool insulation sheet, so I'm hoping to get to higher temps and melt copper soon. I'm using waste engine oil and a blower.

cheers
Mark

[bf109v7]

yes i lowered the comp ratio to 17 to 1. idling boost is about 5psi 3600 to 3800 rpm is about 10 to 12 psi. 3200km's used 77l of fuel.

Thank you very much! I want to use a turbocharcher, but i can profit from your experiance.
Alex

[BoxerOtto]

thanks mark. these ends are actually my toolbox. i'm still experimenting with my foundry and would eventually like to do some bronze. i'm using an old diesel furnace gun to fire it and it works very well. i made some other parts when i mounted the centrifugal charger, i will post some pics now.

[mark_in_manchester]

Very nice!

I've rather limited space, and my 'milling-machine' is a forced marriage between a small 3-axis table and an ancient pillar drill. I envy you a big machine and the stability to clean things up with a fly-cutter like that.

I've got bronze to melt, but the one time I tried to pour in the sand (a plaque for a dead dog which had to survive a marine environment!) it froze before the mold was full - so I guess I need more heat, and I'm hoping the insulation will help.

One day I hope to make a proper bell-housing for my diesel bike...we'll see...

[BoxerOtto]

don't build this

machining mount

pulleys were also poured castings

[BoxerOtto]

They are old machines but they work good. a bell housing would be a cool project. just never enough time for the fun stuff.

[BoxerOtto]

early building 2008.

[BoxerOtto]

rolling chasis

a lot of time spent on turbo

in the end it was disapointing

[BoxerOtto]

machining flywheel

original weight was 24 lbs

removed 9 lbs

added plastic kohler fan

balanced flywheel

engine rpm at idle only went up marginally

no more overall power from this mod but much nicer response quicker through the gears balanced better than stock much smoother running.

[bf109v7]

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Why was the Turbicharger dusapointing? What is better with the supercharger (belt druven compressor). On the pictures i cannot see an intercooler, and the pipe from the compressor (turbocharger) is quite short. And contains not much volume. I think, when the engine sucks after the Intake valve opens, the is a big pressure drop in this pipe and the carger cant refill this before the intake valve closes.
Alex

[coachgeo]

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Why was the Turbicharger dusapointing? What is better with the supercharger (belt druven compressor)....

viewtopic.php?f=32&t=2527 will give some explanation of why supercharger not exhaust powred turbo

[BoxerOtto]

the snail supercharger also did not work. could barely achive .5 psi boost. to large of a unit. being large I thought I could spin it slower than it was designed for on the seadoo because my displacement is 418 cc not 1500 cc.however on the seadoo it needed to run up to 43000rpm. all I could gear it to was about 18000rpm. the load driving it this fast was more than the minimal boost could provide extra power for so it was a slower bike than naturally aspirated. the amr 300 supercharger is positive displacement and geared 1 to 1 provides ample boost and volume for 418 cc. however there are many other mods to the engine that need to be done first, and is not just a slap it on solution, but it works. I will post more on this tonite when I have time.

[bf109v7]

I worked at FEV in Aachen and we had 500 ccm single cylinder engines there to test new cylinder head designs before making multicylinder heads. And we ran then on a professional test bench. With quarz pressure sensors everywhere. There I learned that when you supercharge a single cylinder enginge you need a large volume between the charger and the intake valve. With a small volume, lets say 500 ccm on the 500 ccm displacment enginge the boost pressure was 1 bar when the valve opens and droped to -0.2 when it closes. but you can see the only with a quarz sensor showing this as a curve over the crankangle. An ordinary pressure gage would show constant 0.6 bar.
With an intercooler added and an extra volume from this and its piping the pressure drop during intake was much less.
Of course, this is only for a single cylinder, on a 4 cylinder thre is nearly no change in intake manivolt pressure.
And I am now a retired and have only a small privat workshop and no quarz pressure sensors any more. And only a Yanmar clone and a turbocarger that was left over from a 500 ccm test enginge. And an intercooler. I will give it a try. and post the result here.
Alex

[BoxerOtto]

too much heat. up and over 600c

manuel says 480c + or - 20c max

this blown chamber is from starting fluids, if it wont start on the kick,or rope, or electric then you have another problem that should be sorted.

i'm with you man.if you have the parts try it. its only time , my suggestion is to run bike or engine on a known load to see if the gains are there. there is so much more heat from the turbo and the plumbing and extra weight, i will not go back. that being said i know with more money and experimentation im sure it could be made to work. the supercharger builds tourqe from idle up no waiting,self contained oil system,no blockage on the exhaust where massive heat is made with turbo. the extra heat from the turbo caused the head failure and happened 5000km before the piston cracked. the return oil should also have a cooler from turbo because it makes the engine oil very hot also. you also need stonger valve springs to compensate for boost and i found dropping timing back helped also.my plastic fan blows more air than the cast fins on the flywheel also helping cool.don't forget your pcv venting system with oil seperator otherwise you will be making a big oily mess. oh and of course i machined the top deck of the piston to achieve 17 to 1 comp ratio and can still kick start down to +5 celcius. good enough for me.

[BoxerOtto]

intercooler just below fuel tank, see finned aluminum tube on supercharger outlet. this season will have water or alcohol injection experimentation.

[bf109v7]

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i'm with you man.if you have the parts try it. its only time , my suggestion is to run bike or engine on a known load to see if the gains are there.

I have the engine in a boat now. Because threre I can measure easy RPM and speed. With a bike on the road with trafic zhis is not possilbe.
I did testing wihtout the Charger, with 2 different Props.
Cold start is no problem here, It does not get coolder than +24 C.
Alex

[BoxerOtto]

if it never gets colder than 24c then controling the heat will be even more of an issue for you. best of luck.

[Blunt Eversmoke]

Hey Otto! Little question: When you decided to supercharge instead of turbo, have you also thought of using the old petrol engine as your supercharger airpump? I mean, instead of straight-shaft cylinder off, you could have welded the ports shut, poured some 4stroke oil into the crankcase, and replaced the cylinder head with a metal plate with two reed valves. Overdrive it with desired ratio to reach your desired boost figure.
No need to buy superchargers, that way

[BoxerOtto]

i don't think the crank could take the twist its only pressed together and driving the trans from one end i'm sure would undo. a lot more messing around but could mabey made to work. the supercharger was ebay at only $280.00 cad. i think the supercharger would have a smoother air delivery. mabey make a billet crankshaft and have it pump on both upstroke and downstroke?more plumbing and weight. i think for now i'll keep this one,it's working well.