RE: GP29 race ported versus none ported 36mm kit   
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RE: GP29 race ported versus none ported 36mm kit - 8/16/2009 2:45 AM   
46u



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I do not own anything 4 bolt right now but if I had to make a guess I would say no a 4 bolt cylinder will not work on a 2 bolt case.

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RE: GP29 race ported versus none ported 36mm kit - 8/16/2009 6:40 PM   
46u



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Parts list
New cases, crank and flywheel
Team Fast Eddie stainless steel crank bearings. (next build I will be trying his ceramic bearings)
Zenoah complete engine gasket kit
Zenoah crank seals
ADA billet intake manifold
Do to hearing about some failures with the CY wrist pin bearing I am going to get a Zenoah bearing.
I all so have a WT813 carburetor that should be here tomorrow.

I have a new coil, flywheel shroud, pull starter assemble and cylinder cover but might use the ones off my stock 26 that is in my 5b SS now.



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RE: GP29 race ported versus none ported 36mm kit - 8/16/2009 11:01 PM   
46u



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Here is the template mounted to the cylinder. The red is where I will have to cut.

I am having problems getting the template on the case like I want but it is looking like it is going to take less cutting then the cylinder.



< Message edited by 46u -- 8/24/2009 10:33 PM >


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RE: GP29 race ported versus none ported 36mm kit - 8/17/2009 12:46 AM   
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Very nice list of parts your are building!

As for the templates, when you say they are not \going on like you want them to, do you mean that they are not aligning up where the ports need to match with the passageways of the crank case?
As for securing the templates while you work on the passageways, try securing them to the head with a nut or 2 nuts and see if they will line up better to your liking.

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RE: GP29 race ported versus none ported 36mm kit - 8/17/2009 1:09 AM   
46u



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In the instructions that come with the templates you tap one with a 5mm x.8 tap. This one of coarse is for the cylinder to be held on with the cylinder bolts. The other one is drilled with a number 8 bit which is for the case. I drilled it on my big drill press and had it in a small drill press vise but did not mount the vise to the table so it could move a little to use the holes all ready there as a guide. When I go to bolt it to the case which the instructions recommend using flat head screws so the tapers help to line the template up the holes are off just a little and one bolt will not go in with out forcing it. It wants to cock to one side.

I ground one of the holes out just a little bit but the template is not lining up very well. If I take the and bolt the other template to they cylinder like in the above picture the template for the case falls right on to the bolts no problem. Then only thing I know to do is drill the holes out just a little bigger and use regular head screws and adjust the template as needed. Hope this makes senses as my sinuses are really messing with me.

The templates are only a guide and after roughing in you take half the case put the cylinder on and match them up one side at a time. All in all I think it will turn out OK. Now I am waiting on my practice cylinders to get here.

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RE: GP29 race ported versus none ported 36mm kit - 8/17/2009 3:37 AM   
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Great write up so far. Believe me, I am going to school on you. When you get done, if you are impressed, I might try the same thing on my CY29.

Dennis

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RE: GP29 race ported versus none ported 36mm kit - 8/17/2009 8:20 AM   
splcrazy


 

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hey can you show pics when you have ported it and keep the template on so i can see the difference . im interested in the templates but never bought them cos i have no idea how they work

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RE: GP29 race ported versus none ported 36mm kit - 8/17/2009 4:49 PM   
46u



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quote:

ORIGINAL: splcrazy

hey can you show pics when you have ported it and keep the template on so i can see the difference . im interested in the templates but never bought them cos i have no idea how they work


I plain on it. Right now the hold up is waiting on some practice cylinders to get here. I need to find out what burrs and speed of the rotary tool I need before garbing my $115 top end LOL!

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RE: GP29 race ported versus none ported 36mm kit - 8/18/2009 1:23 AM   
46u



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My 813 carburetor arrived today.

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RE: GP29 race ported versus none ported 36mm kit - 8/18/2009 8:18 AM   
splcrazy


 

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so the red circles in the pic , is that for taking off material at an angle to imitate the looks of the zen head , or is it an indication to take off the material going all the way straight down .

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RE: GP29 race ported versus none ported 36mm kit - 8/18/2009 6:34 PM   
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those templates look a bit severe with the amout of material to come out, the 2 transfers on that side will be huge and nearly touch the intake port, are sure you got it on the right way? you'll have to take huge amount out the case as well. I've never seen a cylinder or case with that much material removed.

And a note on zenoah engines, as you know they are built by komatsu now if you have ever run komatsu heavy equipment you'll know why I put in a sad face....komatsu themselves build 5hite, just hope they leave the zen factory alone to do their thing

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RE: GP29 race ported versus none ported 36mm kit - 8/18/2009 6:54 PM   
46u



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The cases has WAY less to take off then the cylinder and you do not take the metal out all the way down you only bevel it for smother flow and yes the template is installed the correct direction. With the templates you do make the opening some bigger but all so match the case with the cylinder.

This is the the same shape they use on this engine.
http://www.cc-racingengines.com/index.php?page=shop.product_details&flypage=flypage_images.tpl&product_id=264&category_id=26&option=com_virtuemart&Itemid=53

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RE: GP29 race ported versus none ported 36mm kit - 8/19/2009 12:48 AM   
46u



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I believe these pictures will show the POOR flow from the transfer ports in the case to the cylinder. All so I think it show the templates are fairly accurate. I have done nothing to either the cylinder or cases yet.


< Message edited by 46u -- 8/24/2009 10:33 PM >


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RE: GP29 race ported versus none ported 36mm kit - 8/19/2009 2:08 AM   
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wow, that's bad. here's my old ONB 28.5 reed ported head lined up...the difference is very clear...Sean obviously uses templates for his port jobs...i just built 2 fresh 36mm ported top ends and they both look like this one...no need for me to do anything....I've always dealt with ONB and this should encourage others to do the same, i'm afraid that esp job looks pretty poor in comparison. I never realised it had already been done that's why i thought the templates looked severe as mine have always matched up nicely.



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RE: GP29 race ported versus none ported 36mm kit - 8/19/2009 2:11 AM   
46u



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Has anything been done to the above case? Is it a Zen or CY case?

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RE: GP29 race ported versus none ported 36mm kit - 8/19/2009 2:14 AM   
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cy case...stock

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RE: GP29 race ported versus none ported 36mm kit - 8/19/2009 2:17 AM   
46u



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Thanks as I am new to porting a 2 cycle. All I have ever done to a 2 cycle cylinder before this is after I bored it is to chanfer the ports to keep the ring from catching on the openings and breaking a ring.

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RE: GP29 race ported versus none ported 36mm kit - 8/19/2009 6:23 PM   
46u



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OK guys I am a little disappointed in you. Take a look at the last couple of pictures I posted and see if you notice what is wrong. I was wanting to see who would notice it first and someone on HBF pointed it out first.

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RE: GP29 race ported versus none ported 36mm kit - 8/19/2009 6:30 PM   
46u



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Does not much matter for the question I had. Here is a picture with the cylinder turned the proper way. LOL Do I bevel or blend the blue area?



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RE: GP29 race ported versus none ported 36mm kit - 8/19/2009 6:57 PM   
savagecommander


 

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no, thats covered by the piston

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RE: GP29 race ported versus none ported 36mm kit - 8/19/2009 7:01 PM   
46u



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Thanks for your input I keep getting conflicting opinions on this and I am more incline to agree with you as it does not have much or anything to do with flow to the transfer ports.

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RE: GP29 race ported versus none ported 36mm kit - 8/19/2009 7:28 PM   
46u



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quote:

ORIGINAL: mooman007uk

are sure you got it on the right way? you'll have to take huge amount out the case as well. I've never seen a cylinder or case with that much material removed.



I think you are correct and the templates are on wrong on the cylinder after doing more checking but still have a lot of material to remove.

Thanks guys for all the input and suggestions! Please keep it coming. If you look at the last picture with the cylinder on properly it is the exhuast side that needs all the work.

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RE: GP29 race ported versus none ported 36mm kit - 8/24/2009 8:38 PM   
46u



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Been sick and still not feeling well. Got my first practice cylinder today and it is a Zen and is MUCH nicer in the transfer port area. The Zen cylinder is open much more then the CY. Just setting the template on the Zen it is easy to see it would take VERY little to make it match the template. I am hoping to be receiving some CY practice cylinders as well as I am starting to question if the extra $40 is worth it for DDM race porting job.

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RE: GP29 race ported versus none ported 36mm kit - 8/24/2009 10:32 PM   
46u



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Look how close the transfer ports are to the intake ports on this Zen cylinder and this is only a 32mm bore! The Zen cylinder gives me a much better idea of how to open up the ports on the CY cylinder.



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RE: GP29 race ported versus none ported 36mm kit - 8/24/2009 11:17 PM   
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Can you post a pic of the DarkSoul porting template on that head too? I want to get an idea of just how much excess material Zen heads have too.

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