Triumph 500 twin

[John Roberts]

Photos below show left hand crankcase outside machined. Roughing was done with a 3/4" single flute cutter (shearhog). For  semi finish
I used a 10 mm corner rad end mill. The tool path the cam software generated for this machining operation alone had 138,000 lines of G code!  Finish paths were taken using 6 mm corner rad end mill.
1 1/2 KG of swalf removed from this piece. Now I have to go though the same process again for the timing side.

[John Roberts]

Photos!

[Admiral_dk]

Huge amount af Swarf - but Very apparent that there was a major part of a Motorcycle Engine hidden inside the chunk of aluminium       

Per

[John Roberts]

Right hand crankcase roughed out. This  took about a hour to machine. The finishing paths will take much longer.

[Art K]

John,
Following along enjoying the process as the engine starts to take shape!
Art

[John Roberts]

Most of the external machining has now been done on the right hand case.  5 different size cutters used and 16 machining operations completed. Big relief.  I do however need to flip it over and finish off  a few areas also some manual cutting required. So far so good!

[Roger B]

That's some fine metal sculpting   

[John Roberts]

Thanks guys.
 I couldn't resist a rough assemble to see what it looks like.

[Admiral_dk]

A Very Very nice family shot         

Per

[jcge]

That looks really great !!
John

[John Roberts]

Today I machined the gearbox cover which needs finishing up and polishing before counter bored screw holes are cut.

[John Roberts]

Outer gearbox cover finished. Inner cover made

[jcge]

Beautiful work John.

[John Roberts]

Many thanks jcge.

Photo shows a part that does not look much, but ended up being time consuming to make and fit to crankcase and chain case inner.
Still loads of work to do on the cases before moving on to making the moving parts for this engine.

[jcge]

That looks like plenty of work to me. The hairline fit around the case and cover contour is superb.