| 10th January 2007 |
| If At First You Don't Succeed.....???? |
| Hit it with a big hammer! If I were to tell you how frustrating it is to perfect this re-circulating oil system on the PSR Weslake, it would be a gross understatement! |
| This past Sunday saw the trial running of the motor with the new "shuttle valve" installed, as mentioned in the last news update. Well, it sort of worked, but not quite! The motor still blew a considerable amount of oil out through the breather, but not nearly as much as last week! |
| Well, that convinces me that fitting this valve was the correct thing to do, but in it's present state it is not able to pass sufficient volume per revolution to overcome the volume of air/oil pushed out of the crankcase. "Increase the capacity of the shuttle valve", I hear many of you say. Not as easy as that! |
| The real underlying problem is real estate. The Weslake is a tiny motor, so the volume of the atmospheric internal oil resevoir I have created in the motor is very small in comparison to a modern machine. |
| A modern laydown GM or Jawa for instance has all of the timing chain casing, from the bottom chain wheel, right up to and including the valve cover as its resevoir. The breather then exits the motor at a point well away from the filled oil level in this casing. Oil can splash about and be blown copiously from the crankcase without ever going up and plugging the breather pipe. |
| With the pushrod Weslake, there is very little opportunity for oil or air to freely breathe up to the valve cover. It does not have a huge open void for the camchain to pass through which would act as a very handy increased resevoir volume. In fact in the Wessie, there are only two small holes by the side of the pushrod cam followers to allow oil pumped up to the valve gear to gravity drain back down to the bottom resevoir. |
| In essence, I can't get my breather pipe exit far enough away from the filled oil level. It works fine for a few revolutions, but as soon as any sort of pressure builds in the resevoir, oil is pushed up into the breather effectively plugging it. It then is no longer a free breather so further pressure builds in the resevoir until it pumps lots of oil up the breather pipe. |
| It really is a dilemma, and at one point early this week I was going to admit defeat and return to a total loss oil system. However, I spent almost three hours last night re-designing the crankcase oil return, incorporating into it a large volume breather located at a strategic point in the line. |
On paper at least I'm confident that we will be another step closer to ultimate success! If there was one good thing to come out of last weekends testing, it was the newly balanced crank. I had mentioned that I was going to have a go at improving the balance of the motor now it has been layed down. Well, it worked. The thing is smoother than it ever was as an original upright! Thanks Bob! (Bob knows who he is). |
| I hope those of you interested have some understanding of what I'm doing from my website descriptions. It's hard to really convey everything in words, but hopefully it'll convince you to never try to do what I'm doing! |
That way it ensures I will own the only laydown re-circ pushrod Weslake ever built! |
| Next test run is scheduled for this coming weekend so keep checking back for details. |
| Regards, Phil #21 & Michael #2. |
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| 4th January 2007 |
| Back To The Drawing Board! |
| Well, nothing is ever easy in Research and Development. After trying all sorts of things to create the optimum pressure differential between the crankcase and the internal oil resevoir, I was not able to acheive a satisfactory result. |
| In fact, the last motor running test ended up with a massive plume of oil spraying through the air in my workshop, all over my tools, the bike, the floor, the ceiling and me! Oil blew out of the brather pipe at such a velocity it was frightening! |
| So, I put my thinking head back on and came up with an idea which I believe stands a great chance of working. I have custom made an internal air shuttle valve, which should relieve pressure from the internal oil resevoir and ultimately the breather chamber, back into the crankcase as the piston rises. |
| I'm quietly confident this will solve the issues, and if it doesen't completely cure the problem, I will at least know the direction I need to go. Unfortunately, the addition of this shuttle valve has meant a complete stripdown of the motor and splitting of the crankcases once again. |
| I will also take this opportunity to rebalance the crankshaft as I did notice during test running that the bike was quite vibratory. This is due to the balance of the crank not being entirely correct with the motor in its laydown orientation. I had been assured that this would not present a problem, but it is something I think I can definately improve upon. It makes sense to do this while the crank is out of the bike, hopefully for the final time. |
| So the long toil continues! Please do keep checking back, and feel free to send me a bottle of champagne once I have achieved a successful running motor! |
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