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ER5 Engine Swap / Build

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Re: ER5 Engine Swap / Build

Post by Via » Thu Sep 06, 2018 9:30 am

Looking good :thumb:
Hoggs wrote:
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I agree totally with @Slowlycatchymonkey



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Re: ER5 Engine Swap / Build

Post by fastbob » Thu Sep 06, 2018 10:47 pm

I made a sump gasket this evening, this one was relatively easy being composed of straight lines . To do the holes I made a punch tool by sharpening the inside edge of a locating dowel using a Dremel . I wonder if you can download gasket patterns from the internet ?
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Re: ER5 Engine Swap / Build

Post by fastbob » Sat Sep 08, 2018 1:29 am

I still haven't got the pistons in but I couldn't resist sticking the top end on ( not bolted up obviously ) just to see what it looks like. I think the original paint on the cylinder head , although a bit lighter, blends in well .
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Re: ER5 Engine Swap / Build

Post by fastbob » Wed Sep 12, 2018 6:35 pm

On the weekend I popped all the valves out and lapped them to the seats . I found a little bit of rust inside two of the valve seats but not on any of the faces . I got my new piston rings today and the first thing I did was measure all the end gaps . To my relief they are all at the small end of acceptable limits , brilliant ! Final assembly tonight then . Please don't let me f**k up !

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Re: ER5 Engine Swap / Build

Post by Mickly » Wed Sep 12, 2018 8:34 pm

How do you hold the gasket paper in place while you are profiling it?
I’ve been looking at the price of some of the Gaskets I need for the Trophy and it’s made my wallet quiver.
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Re: ER5 Engine Swap / Build

Post by fastbob » Wed Sep 12, 2018 10:54 pm

Mickly wrote:
Wed Sep 12, 2018 8:34 pm
How do you hold the gasket paper in place while you are profiling it?
I’ve been looking at the price of some of the Gaskets I need for the Trophy and it’s made my wallet quiver.
Not quite sure what you mean but anyway, what I do first is place the cover on the paper and draw round it with a fine biro . Then I take it off and scribble all over the jointing face with a marker pen several times and while its still sticky I put it back onto the paper using the drawn outline as a guide . This should make a print of the inner shape . Then , with the cover still in place,I use a bit plastic tube dipped in paint to mark all the hole positions. Next I punch out all the holes using a sharpened locator dowel . Lastly I carefully cut the whole thing out with a scalpel . If the gasket has all straight edges I skip the printing stage and just use a ruler to draw the inner shape and a bit of the old gasket to draw around the wavy bits where the holes go . I'm sure there are other ways of doing this but I just kind of made this up as I went along.
Last edited by fastbob on Thu Oct 03, 2019 8:00 pm, edited 2 times in total.

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Re: ER5 Engine Swap / Build

Post by fastbob » Wed Sep 12, 2018 11:27 pm

After much fiddling about I got the pistons into the cylinder block . Not so easy with new rings and freshly honed bores .
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Re: ER5 Engine Swap / Build

Post by Mickly » Thu Sep 13, 2018 1:54 pm

fastbob wrote:
Wed Sep 12, 2018 10:54 pm
Mickly wrote:
Wed Sep 12, 2018 8:34 pm
How do you hold the gasket paper in place while you are profiling it?
I’ve been looking at the price of some of the Gaskets I need for the Trophy and it’s made my wallet quiver.
Not quite sure what you mean but anyway, what I do do first is place the cover on the paper and draw round it with a fine biro . Then I take it off and scribble all over the jointing face with a marker pen several times and while its still sticky I put it back onto the paper using the drawn outline as a guide . This should make a print of the inner shape . Then I use a bit plastic tube dipped in paint to mark all the hole positions. Next I punch out all the holes using a sharpened locator dowel . Lastly I carefully cut the whole thing out with a scalpel . If the gasket has all straight edges I skip the printing stage and just use a ruler to draw the inner shape and a bit of the old gasket to draw around the wavy bits where the holes go . I'm sure there are other ways of doing this but I just kind of made this up as I went along.
Cheers Bob, I’ll give it a go when I’m ready - the best place to buy decent gasket paper is?
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Re: ER5 Engine Swap / Build

Post by fastbob » Thu Sep 13, 2018 2:06 pm

Mickly wrote:
Thu Sep 13, 2018 1:54 pm
fastbob wrote:
Wed Sep 12, 2018 10:54 pm
Mickly wrote:
Wed Sep 12, 2018 8:34 pm
How do you hold the gasket paper in place while you are profiling it?
I’ve been looking at the price of some of the Gaskets I need for the Trophy and it’s made my wallet quiver.
Not quite sure what you mean but anyway, what I do do first is place the cover on the paper and draw round it with a fine biro . Then I take it off and scribble all over the jointing face with a marker pen several times and while its still sticky I put it back onto the paper using the drawn outline as a guide . This should make a print of the inner shape . Then I use a bit plastic tube dipped in paint to mark all the hole positions. Next I punch out all the holes using a sharpened locator dowel . Lastly I carefully cut the whole thing out with a scalpel . If the gasket has all straight edges I skip the printing stage and just use a ruler to draw the inner shape and a bit of the old gasket to draw around the wavy bits where the holes go . I'm sure there are other ways of doing this but I just kind of made this up as I went along.
Cheers Bob, I’ll give it a go when I’m ready - the best place to buy decent gasket paper is?
I just buy it off eBay , its called Flexoid

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Re: ER5 Engine Swap / Build

Post by fastbob » Fri Sep 14, 2018 8:46 am

A small setback , one of the cam shaft journal bolts pulled the thread clean out before reaching the torque setting ( 12 inch pounds ) so I'm going to have to Helicoil it . Not a problem in itself but I wish it wasn't in such an important place . I think I'll fit a manual cam chain tensioner later on because the one in it seems to require a bit of "help"

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Re: ER5 Engine Swap / Build

Post by megawatt » Fri Sep 14, 2018 9:05 am

I've replaced all the M7 rocker cover threads, in the cam caps, on my GSX race engine. Not a difficult job, but serious if it goes wrong. I'm sure you'll cope mate.
Bike work, I come to you and you can learn to do it yourself click the link below for more info
http://themotorbikeforum.co.uk/viewtopi ... 5&p=949652

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Re: ER5 Engine Swap / Build

Post by fastbob » Fri Sep 14, 2018 2:04 pm

megawatt wrote:
Fri Sep 14, 2018 9:05 am
I've replaced all the M7 rocker cover threads, in the cam caps, on my GSX race engine. Not a difficult job, but serious if it goes wrong. I'm sure you'll cope mate.
Yeah, I know what you mean , I did all the M7 rocker cover threads in my previous GSXR 1100 L . Would you recommend a hand drill to enlarge the hole prior to tapping ? I can't remember what I did last time . By the way , I've just remembered what happened when I had the cam shafts out on that bike . Nearly every one of the bolts snapped when they were un screwed . In every case it was just under the bolt head so there was plenty of shaft remaining that screwed out with finger pressure . I reckon some heavy handed" mechanic " had used foot pounds instead of inch pounds !

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Re: ER5 Engine Swap / Build

Post by megawatt » Fri Sep 14, 2018 4:06 pm

I just used the supplied tapping drill.
Bike work, I come to you and you can learn to do it yourself click the link below for more info
http://themotorbikeforum.co.uk/viewtopi ... 5&p=949652

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Re: ER5 Engine Swap / Build

Post by fastbob » Fri Sep 14, 2018 7:03 pm

megawatt wrote:
Fri Sep 14, 2018 4:06 pm
I just used the supplied tapping drill.
That's what I'm going to use but did you use an electric drill or a hand drill ?

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Re: ER5 Engine Swap / Build

Post by megawatt » Sat Sep 15, 2018 12:07 am

Electric pillar drill and a hand held vice to make sure it was exactly 90 degrees.
Bike work, I come to you and you can learn to do it yourself click the link below for more info
http://themotorbikeforum.co.uk/viewtopi ... 5&p=949652

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