35mm Carb holder rubbers manufacture - Reed side

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KR-1R
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35mm Carb holder rubbers manufacture - Reed side

Post by KR-1R » Mon Oct 05, 2009 8:42 am

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others on the forum have worked around the problem though ingenuity
there are other issues beyond the, first and probably hardest part,
of mounting the 35mm PWK


Those currently interested in the 16065-1196 reproduction part...
CHARLES ++
RGVLEE ++
JARNO
SMITHYRC30
NOS EXUP ++ (green, premix)
KWACKMAN12
SHARKY
HEPPI
Brian Waters
MJ43 ++
Falconman ++++
Scooble
Corvine
Tescr500 +
Edgar90 ++
andy b
Steely

=====
the-elf
scottakr ++
kwakon
frog32
mgtkr1 ++
satarn ++
dirk
scoobydo ++

the manufacture is going ahead regardless of numbers
but if everyone wants a pair theyll be on the waitlist
PM me if you want to be included.

price will be cheap as I can have them made - more than likely cheaper than OEM !!
I only wish at the time I had purchased many of the airbox side which were way cheaper than the 1196 and are more difficult to reproduce


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Last edited by KR-1R on Thu Jan 14, 2010 9:10 am, edited 31 times in total.

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KR-1R
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16065-1196

Post by KR-1R » Mon Oct 05, 2009 8:48 am

These are the original reed side rubbers for the PWK35...
maybe the last unused pair in existence?
Image
still with the spidery mold release residue from the factory - NOT perished
Image
what you dont really see here is how the aperture of the rubber actually nozzles the flow from 35 circular to a smaller rectangular cross section spreading intake across the reed cage.
The intention is to reproduce this feature and still accomodate those who wish to run VForce as well (much bigger opening)
So the flange plate will have be a much larger hole but will be mostly filled back in down to original size.
Image

OK I'm a bit premature here because production of the replica part is only part underway...

The backing plate is at the waterjetters (was cheaper than laser),
dont expect the case side to have the same imbedded gasket as the original which maybe too tedious to reproduce

hopefully I'll be happy with the results of the plates later this week will post pics as soon as I move to next stage rubber/urethane casting
careful selection of the urethane is required to provide temperature and oil/fuel resistance
There is possibility of colour eg racey RED or GREEN for example - maybe you want BLUE to match your Moose water hose

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kwackman12
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Post by kwackman12 » Mon Oct 05, 2009 7:44 pm

PM'd you, Looking at the originals were they still running the oil injection system on the race bikes?
KR1 race bike
ZXR 400 Race Bike
Aprilia RS250

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KR-1R
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Post by KR-1R » Mon Oct 05, 2009 9:30 pm

to simplify the mold I intend to leave the injector hole blank/filled

it should be easy enough to drill out if you want to run the injectors.

The 'R' and 'SP' were still road bikes and ran oil injection.
Last edited by KR-1R on Mon Sep 06, 2010 11:10 pm, edited 1 time in total.

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Post by KR-1R » Tue Oct 13, 2009 8:11 pm

STAGE 1 - COMPLETE

THUMBS UP so far - initial small run of flanges, now the molds can be taken off the original parts to suit the manufactured plates


Image
bolt holes slightly oversized so become partly rubber coated.
Centre hole is well oversized - final aperture in rubber down to standard dimensions

Image

next sandblasting flanges then (Stage 2) rubber molds, casting, bonding onto the plates.

(Stage 3) can the airbox sides be duplicated?
Last edited by KR-1R on Tue Oct 13, 2009 10:41 pm, edited 2 times in total.

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Post by TwoStroke Institute » Tue Oct 13, 2009 9:26 pm

What's the ID of the carb spigot?
crochet & croquet

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KR-1R
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Post by KR-1R » Tue Oct 13, 2009 10:15 pm

PWK35, 35QAS is 41-42mm carb OD (outside diameter carb downstream side) / Rubber ID
:-k later on might look at having some done to 46mm OD :-k

standard 'R/SP' entry into reed cage is rectangular round oval 41mm wide x 31mm
Vforce entry is approx 47mm x 38mm

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scooble
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Post by scooble » Wed Oct 14, 2009 5:39 am

i am potentially interested in a pair of these (depending on price), is it possible to quote a ballpark cost?

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the-elf
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Post by the-elf » Thu Oct 15, 2009 10:24 am

I'll be interested in a pair as well.
-- Lets go Racing
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ScottaKR
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Post by ScottaKR » Thu Oct 15, 2009 11:09 am

Interested as well (depending on price).
KR250 Tandem Twin (Naked) :mrgreen:
KR1 Red/White
KR1S Track Bike (has been put on hold for now)
ZXR750 H1 (Winter project)

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KwakOn
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Post by KwakOn » Thu Oct 15, 2009 11:44 am

also interested. 8) 8)
.. Image ..

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Post by frog32 » Thu Oct 15, 2009 4:01 pm

interested aswell =D>
2 strokes our way of life :-)

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Post by mgtkr1 » Thu Oct 15, 2009 7:48 pm

also intrested, in two sets if poss.

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Post by rgvlee » Sat Oct 17, 2009 3:40 am

2 sets for me mate.

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Post by satarn » Sat Oct 17, 2009 11:40 am

Two sets for me please
regards Krish

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