Polishing engine internals?

chrisk

Hero member
When I raced Speedway solos, the Jawa engines I used had all the internals, rockers, crank etc polished, in that they weren't just standard casting finishes.

Q: Would there be any significant HP increase by doing this? I wouldn't think they'd do it if it wasn't benificial. Any ideas?
 
It's done actually for two reasons I thin, one (and the major point) is what Cam already wrote, the other is that on polished surfaces, Oil does not stick as much as on rough surfaces. Less oil sticking means less weight gain during operation which means better revving of the engine. That's why today they use PTFE on such surfaces.

HTH
 
Strictly for reliability, no HP gain whatsoever...

Experience is also called for, cannot just grind and polish anything you want.  Need to know where and how much material may be removed without weakening the component.

piet
 
Thanks for the input: So how did the Ducati mechanics know where to drill out the gears and the like on the Green Frames without compromising componant strength, and has anyone tried this with a 1000 triple? I figure it'd recuce a large amount of spinning mass, giving a significant HP increase.
 
Hi Chris,

Keith and Red did a lot of drilling of internals, which partly reduced rotating mass and partly improved oil flow. I wouldn't sign in blood that this does not improve the power-output, as reducing mass and friction does reduce loss of power, which can only result in a bit more torque and power at rearwheel, but Piet is right: it is mostly done to improve reliability and bring down weight, less so much to gain HP (you can gain more power with easier methods).

How did the Ducati guys do know? Well - try and error combined with experience I would say... Just like Keith and Red are doing it. Keith has posted a while ago a pic of some lightened parts like cam wheels, oil-pump-wheel, primary drive etc., maybe he can post it again as I could not find it. The parts looked like a piece of art to me and the weight-gain was (relatively) significant (primary drive something like 400 - 500 grams I think?!?).

The main point though is as Keith stated in that very same thread: stay on the safe side! It does not pay off to go to the edge and take the risk of a braking part at 8.000...  ;)
 
engine I am working on at the moment, drilled, machined down, balanced, etc

Primarydrive.jpg


No1web.jpg


bloody cranks are hard work on the machinery machining them down to shape, burn through cutting tips
 
back in the day polishing was done for reliability. i suppose reduced windage was a bonus...
part would first be checked for cracks using a magnetic field ... magnaflux is what we call it in the colonies
casting marks or seams, which can become stress risers leading to component failure, were ground down
one had to mind the direction of the grinder eg; connecting rods were ground lengthwise not across the beam
until bit was reasonable smooth and free of said casting lines/marks/etc before treating to a series of flapper wheels
with coarse to finer grits until quite shiny and smooth, component would then be balanced, touched up with flapper wheel, balance checked again before the part would be shot blasted for surface hardness. a rather labor intensive operation
but one that payed dividends at the track. as the saying goes "you first have to finish"

polishing isn't limited to cast bits. eg; valve stems are routinely micropolished with scotchbrite pads and cylinder bores are planished after honing. with laverda polishing the studs where oil travels can offer some degree of flow improvement.

if you are having it done it becomes a matter of what is cost effective. likely cheaper to have carillos installed than polish std rods whereas clutch parts are very cost effective

in these 750 parts you can see the OD reduced and polished. cooling holes also lighten and the cooling holes are all  chamfered to reduce stress risers, same with lightening holes in drive sprocket. this one set up to use a duplex with the inner row removed for better ventilation of the 750 assy


 

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Not polishing but also as stated lightening. I had a 100 Rotax kart engine that had
connecting you could shave with, also polished almost to mirror finish. It revved freer than
my TKM engines and never failed. As an aside I might go back to karting in the Vintage class.
No expensive medical :D :D :D :D :D :D :D :D. Got an old Dino chassis lined up.

Andy

Just got to loose 2-3 stone >:( >:( >:( >:( >:( >:(
 
andychain said:
I had a 100 Rotax kart engine that had connecting you could shave with ...

There's no need to do that Andy. I know you've mentioned that money is a bit tight until your compo claim comes through, so I'd be happy to send you a razor if you can't afford to buy one  ;)
 
Dellortoman said:
andychain said:
I had a 100 Rotax kart engine that had connecting you could shave with ...

There's no need to do that Andy. I know you've mentioned that money is a bit tight until your compo claim comes through, so I'd be happy to send you a razor if you can't afford to buy one  ;)

...and I'll help you make it last:

[youtube]http://www.youtube.com/watch?v=gjSkgz3-2Ig&feature=player_embedded#![/youtube]

8)
 
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