Twin Glow
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Camshaft 11−23−01
flat to fit oil pump
.562
1.812
.625
3.875
.625
.250 dia.
Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.2.16 system
Drawn by Glen Bond
.490 dia
Saito Cam Lobe Timing
65 deg. overlap
opens closes intake : 40 btdc 60 abdc exhaust : 75 bbdc 25 atdc
This is the Saito timing Saito FA200Ti cam timing:
BDC 180 90
7−30−03
270
90
135
45
225
315
BECO 2.0 Cam. lobe timing
View from front of camshaft
TDC
180
0 rotation
TDC
90
Intake Lobe on Cam Exaust Lobe on Cam
BDC
Drawn by Glen Bond
180
Drawn with XFig 3.1.4 protocol: 3.1 on a Linux 2.0.3 system
270
270
rad
Front View
/8 11
ius
1.25 0 ra dius
1 3/8"
3.100"
Top View
9−3−00
right side
Crankcase − Left Half
left side
Oil Channel
Front
front
Oil Channel
2.675"
Rear
rear
Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
Drawn by Glen Bond
Right Side View
Left Side View
Front
Oil Channel
May 15 2002
roller bearing double sealed
spacer
Propellor base
Propellor
prop washer
Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
Drawn by Glen Bond
Front cover
3.625
Details of prop end of crankshaft
Oil pump
Timing gears
Oil pan
Crankcase
O−ring seal on shaft
Back cover
4−40 0.540"
0.740"
Connecting Rod 11−10−01
This drawing not drawn to scale
rod cap screws
(13/32")
0.4062 dia.
Cut at this line to seperate the rod and cap
0.500"
drill 1/2"
0.325"
Hollow out 0.080 deep with 1/4" ball end mill
.2500 dia.
0.360"
last updated 11−Dec−05
0.100"
Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.4.26 system
Drawn by Glen Bond
5 − size cap to 0.360" and tap threads (4−40) in the rod. 6 − drill out the rod cap for screw clearence (7/64). 7 − attach rod cap to rod blank and mount flat in the mill. 8 − drill and ream the hole for the big end. 9 − drill and ream the hole for the small end. 10 − drill the holes for the sholder radius’, use a 1/2" endmill. 11 − cut (using an end mill) the straight sides. 12 − put the rod on the rotary table and round the small end.
(this step is not necessary if the cap is cut accurately.)
3 − cut the cap off from the rod. 4 − mill the ends of the rod and cap flat and SQUARE!
Countersink .100" with a 3/16 endmill.
2 − drill 2 holes for the rod cap screws 3/4 inch deep.
Mount the blank in the mill vise − vertical.
countersink screw 0.100"
1.850
.435 dia.
1 − Cut a blank 0.75 wide by 3 inches long from 0.250 thick plate.
Material: 6061 aluminum, 1/4" thick
Step by step directions for making a rod
0.550"
0.375" Dia.
0.275"
X
0.275"
X
Crankshaft
9−2−00
0.275"
0.300"
Oil passages Use # 55 drill (0.052")
0.275"
0.355"
Updated 1−1−06
Crank shaft is turned from 3/4 X 1−1/2 HRS flat bar Turn crank journals first, then main shaft and journals. Put bolts at X while turning main shaft to hold from flexing. Crankshaft Stroke = 1.100 Use with a bore of 1.100 to get a 2 cubic inch engine
1.475"
0.550"
1.600"
0.300"
0.690" 0.400"
0.737" radius 0.373" Dia.
Drawn by Glen Bond
0.500"
0.750"
Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
0.4375" Dia.
0.0937" dia. 0.100" deep
0.375" Dia.
3.350"
update: 6−5−04
Cylinder head with dimensions
Bore through for valve guide
Valve Guide detail
Bore to same as port bore
outside dia. same as valve dia + 0.015
1.000
0.125 drill through for valve stem raised 0.050" to fit inside valve spring
0.900
2.375
0.550
ex. valve dia: 0.488 in. valve dia: 0.550
0.925
0.275
Drawn by Glen Bond Feb. 15, 2002
1.000
Raised .040
Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
0.050
Spark plug hole
Port bore: 0.438 Port bore 0.500
intake to rear, exhaust to front.
Note: Make left and right side heads
Cylinder head is made from 2.5" 6061 aluminum bar stock Cooling fins are evenly spaced. Cut with 1/16" wide cutter. Spark plug threads are 1/4−32
Oil Pan
0.150 thick flange
0.335
11−9−00
Thick section for lifter guides.
1.700
2−56 screws
Drawn by Glen Bond
Match to crankcase
Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
0.055 thick flange
0.320
0.440
All dimensions are inches unless noted.
3.140
lifter guide
0.625
0.330"
Piston for BECO 2.0
Make sure this is deep enough for the oil holes to drain into.
0.750"
0.056"
approx 0.028" Size to fit rings
Oil holes 16 holes (more is better)
This drawing is 2X size Updated 11−Dec−2005
0.900"
0.745"
0.125 radius
0.625"
Drawn by Glen Bond
0.990"
0.470"
1−MAR−02 Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.2.16 system
0.330"
0.175"
0.040" 0.120"
Wrist Pin Bore Dia. 0.250"
Piston Dia. 1.096"
Actual size
Drill 1/8"
0.310"
0.090"
0.188"
0.975"
0.650" 1.625"
Drill and tap for 2−56 screw
0.125" 1.875"
Rocker Arm for BECO 2.0 Revised 7−7−03
Drawn 2X Size Drawn and Copyright by Glen Bond 1−1−03 Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.2.16 system
0.092 dia.
0.125 dia.
0.550 dia. intake 0.488 dia. ex.
0.110
0.050 Spring cap approx. 12X size 0.060 1.660"
Intake valve
Drawn 2X Size 0.315
0.240
0.125
Use 60 degree center drill
0.080 0.150 Valve and Spring cap Revised 7−7−03
All dimensions in inches
Drawn by Glen Bond
3−26−02
Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.2.16 system
flat to fit oil pump
.562
1.812
.625
3.875
.625
.250 dia.
Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.2.16 system
Drawn by Glen Bond
.490 dia
Saito Cam Lobe Timing
65 deg. overlap
opens closes intake : 40 btdc 60 abdc exhaust : 75 bbdc 25 atdc
This is the Saito timing Saito FA200Ti cam timing:
BDC 180 90
7−30−03
270
90
135
45
225
315
BECO 2.0 Cam. lobe timing
View from front of camshaft
TDC
180
0 rotation
TDC
90
Intake Lobe on Cam Exaust Lobe on Cam
BDC
Drawn by Glen Bond
180
Drawn with XFig 3.1.4 protocol: 3.1 on a Linux 2.0.3 system
270
270
rad
Front View
/8 11
ius
1.25 0 ra dius
1 3/8"
3.100"
Top View
9−3−00
right side
Crankcase − Left Half
left side
Oil Channel
Front
front
Oil Channel
2.675"
Rear
rear
Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
Drawn by Glen Bond
Right Side View
Left Side View
Front
Oil Channel
May 15 2002
roller bearing double sealed
spacer
Propellor base
Propellor
prop washer
Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
Drawn by Glen Bond
Front cover
3.625
Details of prop end of crankshaft
Oil pump
Timing gears
Oil pan
Crankcase
O−ring seal on shaft
Back cover
4−40 0.540"
0.740"
Connecting Rod 11−10−01
This drawing not drawn to scale
rod cap screws
(13/32")
0.4062 dia.
Cut at this line to seperate the rod and cap
0.500"
drill 1/2"
0.325"
Hollow out 0.080 deep with 1/4" ball end mill
.2500 dia.
0.360"
last updated 11−Dec−05
0.100"
Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.4.26 system
Drawn by Glen Bond
5 − size cap to 0.360" and tap threads (4−40) in the rod. 6 − drill out the rod cap for screw clearence (7/64). 7 − attach rod cap to rod blank and mount flat in the mill. 8 − drill and ream the hole for the big end. 9 − drill and ream the hole for the small end. 10 − drill the holes for the sholder radius’, use a 1/2" endmill. 11 − cut (using an end mill) the straight sides. 12 − put the rod on the rotary table and round the small end.
(this step is not necessary if the cap is cut accurately.)
3 − cut the cap off from the rod. 4 − mill the ends of the rod and cap flat and SQUARE!
Countersink .100" with a 3/16 endmill.
2 − drill 2 holes for the rod cap screws 3/4 inch deep.
Mount the blank in the mill vise − vertical.
countersink screw 0.100"
1.850
.435 dia.
1 − Cut a blank 0.75 wide by 3 inches long from 0.250 thick plate.
Material: 6061 aluminum, 1/4" thick
Step by step directions for making a rod
0.550"
0.375" Dia.
0.275"
X
0.275"
X
Crankshaft
9−2−00
0.275"
0.300"
Oil passages Use # 55 drill (0.052")
0.275"
0.355"
Updated 1−1−06
Crank shaft is turned from 3/4 X 1−1/2 HRS flat bar Turn crank journals first, then main shaft and journals. Put bolts at X while turning main shaft to hold from flexing. Crankshaft Stroke = 1.100 Use with a bore of 1.100 to get a 2 cubic inch engine
1.475"
0.550"
1.600"
0.300"
0.690" 0.400"
0.737" radius 0.373" Dia.
Drawn by Glen Bond
0.500"
0.750"
Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
0.4375" Dia.
0.0937" dia. 0.100" deep
0.375" Dia.
3.350"
update: 6−5−04
Cylinder head with dimensions
Bore through for valve guide
Valve Guide detail
Bore to same as port bore
outside dia. same as valve dia + 0.015
1.000
0.125 drill through for valve stem raised 0.050" to fit inside valve spring
0.900
2.375
0.550
ex. valve dia: 0.488 in. valve dia: 0.550
0.925
0.275
Drawn by Glen Bond Feb. 15, 2002
1.000
Raised .040
Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
0.050
Spark plug hole
Port bore: 0.438 Port bore 0.500
intake to rear, exhaust to front.
Note: Make left and right side heads
Cylinder head is made from 2.5" 6061 aluminum bar stock Cooling fins are evenly spaced. Cut with 1/16" wide cutter. Spark plug threads are 1/4−32
Oil Pan
0.150 thick flange
0.335
11−9−00
Thick section for lifter guides.
1.700
2−56 screws
Drawn by Glen Bond
Match to crankcase
Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
0.055 thick flange
0.320
0.440
All dimensions are inches unless noted.
3.140
lifter guide
0.625
0.330"
Piston for BECO 2.0
Make sure this is deep enough for the oil holes to drain into.
0.750"
0.056"
approx 0.028" Size to fit rings
Oil holes 16 holes (more is better)
This drawing is 2X size Updated 11−Dec−2005
0.900"
0.745"
0.125 radius
0.625"
Drawn by Glen Bond
0.990"
0.470"
1−MAR−02 Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.2.16 system
0.330"
0.175"
0.040" 0.120"
Wrist Pin Bore Dia. 0.250"
Piston Dia. 1.096"
Actual size
Drill 1/8"
0.310"
0.090"
0.188"
0.975"
0.650" 1.625"
Drill and tap for 2−56 screw
0.125" 1.875"
Rocker Arm for BECO 2.0 Revised 7−7−03
Drawn 2X Size Drawn and Copyright by Glen Bond 1−1−03 Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.2.16 system
0.092 dia.
0.125 dia.
0.550 dia. intake 0.488 dia. ex.
0.110
0.050 Spring cap approx. 12X size 0.060 1.660"
Intake valve
Drawn 2X Size 0.315
0.240
0.125
Use 60 degree center drill
0.080 0.150 Valve and Spring cap Revised 7−7−03
All dimensions in inches
Drawn by Glen Bond
3−26−02
Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.2.16 system
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