VOLGASSS auf dem Prüfstand! Besuch bei unserem Heimtuner HT Motoren | Part 1
Hello how are you? Aah okay, super! I have to go back to the other side Bye Puchfans! I don't think anyone is home, only the sheep are here Good to be here! What are we going to do today: We are visiting HT motorbikes One of our regular tuners They make cylinders and cylinder heads for us, let's see what they have to tell us We also have a test bench here! I brought my street Puch Let's see what he does on the rolling road! Then we go quickly to Heiko Hey Heiko! I was just at the front door and no one was home. But of course you are always here Sure I am... sleeping, working everything Not tired? No no, I never sleep Puchfans! We are at Heiko's today and we will go on the rolling road I think? And let's see what you have to say here Interesting! I see something very interesting here already, a racing cylinder! And that is of course for our Puchshop-Racing cup huh Yes this is a very fast one Then we start immediately! This is a very new cylinder? Yes completely new, cast in the Netherlands Oh! There were others who developed their own fast cylinder and we wanted to do the same! With adapter plate, CNC milled Looks impressive! Is that for this season? Are there some racers driving this? Yes 2 in Holland and a few people from Germany There are 29 coming so the party is about to begin! "Jetz geht's los" well said! So you earn your living with HT engines Tuning, how wide is that? Is that just tuning of cylinders? It's a bit of everything I used to be a mechanic, raced and made things for other people.
And then people noticed, Heiko that's a man with feeling Passion, real passion That's where I bring my oldtimer mopeds And that became more and more work What did you start with? Zundapp, Kreidler or something like that? Puch Maxi! I have had a Puch maxi for 14 years! That's how we all start! On a Puch Maxi And after that? This was your own Puch of course Did you also make something for your neighbour or cousin for Kreidler or Zundapp, or was it only Puch? No I only had my own Puch, later I only started I was then too young for a Zundapp and too old for a scooter Then I had a Honda, an MB and an MT I've already seen one, when I arrived here there was an MT Yes that's right, maybe we can go and have a look there later on And of course I also had a scooter really everything And that became more and more and more, so I really had everything. Both 2-stroke and 4-stroke engines. Now I only produce parts Reproduction of parts that no longer exist, development of new products and racing parts like in the Puch-cup That is actually from a moped, a lawn mower to an outboard motor 2 stroke, 4 stroke really everything And I've seen a lot of scooters on Instagram as well, motorbikes actually 180cc, 190cc and 200cc My main job is scooters, but that's not the most fun to do But I do that too Yes it goes how it goes I have developed something and then more and more comes It goes on like that, people know how to find me So now it's a little bit more scooters, but also Zundapp is very big now So I started again with Zundapp parts Oh really? I've seen a nice movie of that recently How many cc did it have? 143cc That doesn't exist, does it? It is 125 or 175, right? Yes that's right, you have a large size 175cc and a 125cc option But 125 is a little bit too little so I thought, I'll make something that sits nicely in the middle A bit more power, without losing flow in the lower block So a bit of a combination between the 2 Yes it is going quite well Now we would like to see what you have in the workshop, can you show us? Then we go for it, come with me! We know the lathe by now, we've seen it at Homoet's and Jens' place. But for turning our cylinder heads you need a special tool, you made that yourself didn't you? Yes, we make everything ourselves, either with the CNC or here. CNC that will come later! So this is the part, we put it in the lathe.
Then you have to check that it is straight, then you turn the cylinder head on the thread And then we have various tools to insert or reposition the O-ring groove. And then we change the product, maybe 100 times, each time we put a new one on. Then a new chisel is put on and then the whole series goes through again.
That's how it goes every week, I hope that's clear. If you have any questions, feel free to email me or leave a comment in the comments. As always actually, it's almost a habit Then we have a milling machine here Yes, a milling machine, that's where the product is fixed, in the lathe the product is rotating Here you can saw, mill and boring for the Gilardoni cylinders And you can make a fourth bearing and in Or with the CNC, but it's the same thing. The 4th bearing, that might be interesting! Puch had of course in the beginning 4 bearings The old models had all 4 bearings.
Later on they didn't make them anymore, I think because of the costs And that is for 3 to 4 HP no problem, 5 HP and even 8 HP also no problem Above that you get a problem, the big-end and the crankshaft is not well supported and then you get a lot of problems. And we don't want any problems. We don't want that at all. Plenty of problems with 2-strokes, especially in races! Oeh I see something there too Yes that is also nice, here we can check the crankshaft You can see that this one has had a stall.
And then we can check everything with this We can put this clock on it and then we can measure the deviation A dash is 1/100th, the tolerance may be one to 3/100ths. Maybe interesting, how much tolerance is allowed on this? Zero is best, but of course that is very difficult. When you measure it here You can also measure it here Then you are at 1 to 1.5/100th of the maximum. Just a quick question, so we know. I didn't know either.
This crankshaft has a deviation of 9/100ths so that is 3 times too much. That's because of the stall Most people drive this, but we make it like new again. This is the only time you are allowed to use the hammer! A brass hammer? Yes, that is correct. Also nice to know, I really did not know anything about it Can we have a look at the CNC machine? We can, but we have to go to the other side! We go to the other barn There we are, what is that! That is the colleague of the month! I don't know if that is good German This is really my friend I bought this one new How long have you had it? Since May last year, 2021 I program it myself, on the machine and on the computer 3D drawing is something I am learning now With this machine, we are of course machining cylinders for our Puch-racing cup But I hear that the cylinder heads are almost ready too? On one side it is! Do you have them around here? Then we can see them right away Here is the first part of the operation Still pretty rough You make that completely in this machine? Yes complete, it does everything Now it is still a thick piece of aluminium, how should I see it? The basis is here, but he does not complete it at once It has to be done in 2 or 3 phases? Always 2 at least. You have to clamp it and you can't mill in there because the head will fly away.
And then you have the top and bottom Yes only from above, but if you have a 4 or 5 axis machine, the machine can also rotate the object So if I have to clamp it two or three times, the machine can do it all at once. That is interesting! But what are these holes for? With Puch you only have 4 cylinder bolts right? Yes, you have seen it right I see 4 too many here Then you can turn it! Is that really the intention? No no, of course not! But you could make it If your engine has a lot of power, the cylinder head will have difficulty withstanding all the force. Then it doesn't seal anymore So what I thought, we'll make the cylinder better too! So the cylinder also has 8 threads. This one is fastened with 8 bolts, so it's much stronger. So it closes better and you get more power.
I understand that, this is really super work How many hours do you spend on this, with one cup? This is not so much, but the cooling fins, he must have done a little bit of that. But the complete removal is super slow with a very small cutter That takes about an hour and a half That's okay and then this is a very fast machine If you have an old CNC, it takes at least 4 hours. Performance and that times 2.5! But you have to program it, the block of aluminium costs 30 Euros That is the most work The cutter head wears out, they don't last forever They also wear out Is that diamond? No hardened steel How long does something like that last? With me, everything always breaks sooner because I don't program it properly, so I don't know how long they can last. I am not that good yet But the result is definitely worth it! The first series are 10 or 20 pieces? 22 pieces! And the inside of the head is good, it's completely finished And then everything still has to be tested, we will definitely come back for that! And we are not even here for that! Because you have a test bench! And I brought my tour pony, I already told you that. I think we can see what a test bench does with it And then we can see if my statement from last week is still true, 7.8 to 8hp
It has been 2 years since I measured that on the test bench. And you have a different test bench, there is also a difference. Because actually you should, that is most reliable, test on one and the same test bench. And even with the same weather That also matters, temperature Humidity, etc. 2-stroke remains difficult Is it an idea that I get my moped out of the bus And then have a look, I'm curious! Getting the Puch out of the bus Then Heiko also has 5 minutes of rest.
What are we going to do? The Puch on the test bench, I have brought a cup Why? Then we can see the difference Because that's what you use a test bench for, perfecting it. And this Puch runs well, starts well, without any problems. And today I want to see what happens with another head What that adds, OR it adds something. I'll take him out and we'll be right back to the test stand. I've never seen this, such a big test bench. Dynostar, Dutch! Yes really, from Rozendaal Yeah I didn't know that either, they are one of the 3 best in the world! They have 3 brands: Dynostar, Dynojet Dynojet we know that's American, probably what they did first After that there were more.
Dynostar also supplies Suzuki worldcup Paris Dakar This is this test bench, but then 4 connected benches for the 4 wheels. You're talking about 4 now, why does he have this? That is for quads Not quarts but quads So even with 4 tyres you can test on this, up to 900hp. Because how heavy, I always hear about test benches: my rollers are 300kg or 600kg Which is the best? There are two types, braked and unbraked.
The expensive benches are unbraked and then you have a weight And at a certain moment the weight is greater than the engine can propel So for example: an engine with 20hp uses a roller of 200kg And it weighs as much as the one outside it. But not this one, this is a braked And it is very light, but inside the roller is a brake And it communicates with the computer and so can compensate for my Puch with 7/8hp Or you need a roller for 50hp, then it brakes more And if I set the brake correctly it goes as fast as outside But we have not prepared that No, but I have done this before so it will be alright. 8 to 10pk is 1 or 2 percent braking There is a chart for that and you can do that on experience. And then I see that everything here is completely isolated? That's right! That's to muffle the sound of course I made it like this: with 225mm rock wool You can test an R1 here at 2 or 3 in the morning and the neighbours won't hear a thing. That is really good The cat doesn't fly away and the sheep don't hear anything They can sleep peacefully Then of course we have the driving wind, we can see that when my Puch is on it Because you use the wind to cool down, otherwise your Puch will be broken after 2 runs And exhaust fumes have to be extracted We can also look at that right away Because without this thing WE are immediately broken Then I'll get my Puch and we'll put it on the test bench, I'm curious! It's on the test bench now, but what can you do with it? The adjustment, what do we adjust? That you need to know first Ignition, nozzles... You can also make a blueprint here, so you can compare parts.
Like with your cylinder head, because I always say: tuning is tuning and you can try all the parts No influences from outside, temperature and humidity are also controlled But what do you really measure? How do you say, Newton meter, torque, top speed, horsepower and acceleration And of course the graph with not only the top power but the whole power Where is the power and how wide is the power And then you can see on the computer the complete power curve What is the most ideal curve for a 2-stroke? For example a Puch Maxi What should the curve look like? Should it rise steadily, then stay the same, then fall off? Yes Then the clutch is important, the nozzle, idle nozzle, throttle needle Yes for example, also the ignition and advance earlier or later The air filter, can it be adjusted? Yes what I have here is actually a basic setup I have a 70cc with a 15mm Bing, original airfilter with a larger bore For me it should not suffer too much for the street. And good acceleration is important for me So Nm and torque is the most important thing I have a Bing without an air mixing screw Yes but it runs fine, otherwise you have to change to a Polini CP: the new Bing actually. Yes I have those on my race Puch, they are really super as a base You can set a lot of things on them. Shall we go then? How does this work, do we do a sort of basic run first? Well first we connect everything: the extraction, measuring tools and air supply Then we do a test, the block is still cold so we have to do several runs. 8, 9 or 12 runs. Then it is well warmed up and then we will do a real test, it is not going to break down is it? We hope so! Then we can laugh! That is fun too! The last 3 measurements we take, then he is well warm And that is how it drives outside Everything is then at working temperature And then we have reliable measurements and we know how it rides outside. Because when we measure and the engine is cold, we have a little bit more power.
Is this true? We often get questions about this, because heat is actually the biggest enemy of 2-strokes, right? Yes, of course, because it gets hot and hardly ever cools down Especially with Puch, a small cylinder and small cooling fins Actually too small, if you compare it with my cylinder you can clearly see the difference Those cooling fins are really big Yeah because if you ride original, 25 or 45km/h that's totally fine too! Because I ride with a tuned cylinder, carburettor and PVL ignition An analogue PVL that also brings some extra power I'm curious how many revs it runs! Shall we start?
2022-03-17 11:01
