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  #51  
Old 02-09-2024, 02:19 PM
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Here's the partially machined cylinders. May drill the fins as they're pretty heavy at 18 lbs. each.







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Old 03-21-2024, 02:05 PM
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And they're finally in.

Rods:




and bearing cages:




If anyone needs 7.440" Sportster rods for a .791 wrist pin and a 1.500 crank pin let me know. Custom orders were for 4 sets minimum. 😐
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Old 04-05-2024, 07:04 PM
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Cylinders cut for clearance so did a quick mockup



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Old 04-05-2024, 07:58 PM
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I had a 100” Sporty, Iron Head, in a rigid frame. Kick start only. Going on an actual road trip once. Got it all loaded down with sleeping bag and leather saddle bags. Got careless in my excitement and didn’t roll it onto the compression stroke before I kicked it and ended up with a broken ankle. Thirty years later; it still hurts


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  #55  
Old 04-05-2024, 08:45 PM
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I had a 100” Sporty, Iron Head, in a rigid frame. Kick start only. Going on an actual road trip once. Got it all loaded down with sleeping bag and leather saddle bags. Got careless in my excitement and didn’t roll it onto the compression stroke before I kicked it and ended up with a broken ankle. Thirty years later; it still hurts


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I empathize. Had a 94" "shovster" based on a '72 XLCH - kick start only. I'm over 200# and it pitched me over the bars when I wasn't paying close attention to where the compression stroke was.
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Old 04-05-2024, 08:48 PM
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Trying for about 11:1 static. Dynamic compression of course will be less due to overlap. We'll try to cam it so we can run 91 octane pump gas mostly. 🤞

Bonneville cams will have more advanced intakes so higher dynamic compression then we'll run race gas.

Heads guy will cc the chambers then I'll have hard numbers to share. Mostly I need to fix the cam lift so I can fix the geometry (stem length). I can mess around with duration to get the dynamic compression where it needs to be.
Very interesting undertaking. I’m just wondering how one can hear detonation without all of the “rush and fury” during a run? Also, I wonder how spark control (advance) is achieved with a magneto?
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Old 04-05-2024, 09:06 PM
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Forgot the titanium wrist pins

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Old 04-05-2024, 09:19 PM
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Very interesting undertaking. I’m just wondering how one can hear detonation without all of the “rush and fury” during a run? Also, I wonder how spark control (advance) is achieved with a magneto?
You tune this on a dynamometer, so it's done way before a run. O2 sensors in the pipes for tuning, they come out once lambda is set. Alcohol is very resistant to detonation, so that helps. Even so we're planning on running it a little rich, Lambda around .8 or so.

Morris has internal flyweights for up to 26 degrees advance. you can tweak the curve (some) with spring selection.

I should update that post, we're now looking at about 15:1 compression to get the most out of the ETOH fuel.
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Old 05-10-2024, 03:17 PM
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Have you made any decisions on the exhaust system?
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Old 05-11-2024, 11:34 AM
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Every time I see this thread title, I can't help thinking of the old Rodney Dangerfield line, "If I had an 8x10, I wouldn't have to work anymore."
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  #61  
Old 05-14-2024, 01:00 PM
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Have you made any decisions on the exhaust system?
Everyone is recommending two single pipes. Recommended outlet size is 3.5" and it's 1.800" coming out of the heads.

I'd like to fabricate the pipes so the expansion is continuous, so we're still working out how to do that.
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Old 05-14-2024, 02:06 PM
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That bike is going to sound... crisp.
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Old 05-14-2024, 05:39 PM
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I’m wondering if it would be easier to just use positive pressure from a turbocharger or supercharger and upgrade the mechanicals for the increased thermal cycle.
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Old 05-15-2024, 05:21 PM
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I’m wondering if it would be easier to just use positive pressure from a turbocharger or supercharger and upgrade the mechanicals for the increased thermal cycle.
Different class for blown engines. Not going there.
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Old 05-15-2024, 08:16 PM
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I still have my XLH-883 Sportster that I bought new in 1988. Really, for what they are designed for, basically a bar hopper, that's more than enough power. I rode it from Raleigh NC to Myrtle Beach SC. The three guys that I rode with all had big Harleys. I had no problem keeping up. Just had to stop for gas more than them because of my 2.5 gallon "peanut" tank. If I ever wear out the 883 top end, which is unlikely, I'd probably make it into a 1200 "just because". I also have a 2013 FXDC Super Glide Custom. No comparison between that and the Sportster. Just so much nicer in every way.
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Old 05-16-2024, 01:25 AM
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I still have my XLH-883 Sportster that I bought new in 1988. Really, for what they are designed for, basically a bar hopper, that's more than enough power. I rode it from Raleigh NC to Myrtle Beach SC. The three guys that I rode with all had big Harleys. I had no problem keeping up. Just had to stop for gas more than them because of my 2.5 gallon "peanut" tank. If I ever wear out the 883 top end, which is unlikely, I'd probably make it into a 1200 "just because". I also have a 2013 FXDC Super Glide Custom. No comparison between that and the Sportster. Just so much nicer in every way.
Think of this more like a really large displacement XR-750.
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Old 05-16-2024, 03:32 PM
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Looks like everything fits.




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Old 05-16-2024, 04:42 PM
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Also, the rollers tend to slide around the crankpin oil holes at high rpm as there's too much oil there..
Is that the notorious bearing skate HD warned about from using synthetic oil... before they started selling it?

About the intake manifold, a custom part?
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Old 05-16-2024, 06:50 PM
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Is that the notorious bearing skate HD warned about from using synthetic oil... before they started selling it?

About the intake manifold, a custom part?
Yes, the manifold is a custom part.

The bearing skate is due to velocity changes as the rollers go through the cycle at high rpm. So, oil management and reducing inertia are the two directions to addressing the problem.
If this doesn't handle it, next is something like titanium nitride rollers in beryllium cages.
Obviously, I hope Plan A works.
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Old 05-16-2024, 08:17 PM
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Beryllium. Strong, lightweight, rigid, tastes sweet and is toxic as all get out.
Perfect!
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Old 05-17-2024, 09:09 AM
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Beryllium. Strong, lightweight, rigid, tastes sweet and is toxic as all get out.
Perfect!
Bingo! We have a winner!
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