One step closer to tears, the boring head has arrived...



Graduations of 0.001"

Sure, I could have used a boring bar in the four jaw, but I would have needed another excuse for some of India's finest tooling

Interestingly, and I must say I know VERY little about this kind of stuff, it has to be run in reverse, and all the cutters are ground to suit, as the head screws onto the Morse taper on a right hand thread so running in the normal (anti-clockwise when facing the headstock) direction would unscrew the head...

Next job is the mounting plate for the piston...

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08 Specialized Langster

Sorry for the stupid question pash.......but.......what exactly are you building/trying to acheive ?

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After all is said and done.......a lot more will be said than done !

Another S1 made out of bits rescued from potential choppers, scrapped engines (including bits from your old one) and tat from EBay

Currently I am fitting some cams, potentially 'properly', which may prevent other people from overlooking various aspects and bending valves or breaking pistons, hence taking a lick off the exhaust valve pockets... Interested to see how an SE536 cam-ed engine rides compared to an SE497 (Lightning) cam-ed engine.

Good job you asked, I had actually forgotten...

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08 Specialized Langster

So its an XB engine in an S1 frame ?

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After all is said and done.......a lot more will be said than done !

No, it is only an XB top end...

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08 Specialized Langster

"....Do not despise the snake for having no wings.......for one day he may become.............'a dragon'!......."

Have you been drinking?

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08 Specialized Langster

No, but all this talk of claying, hoofing, and milling ones valve train does generate a sense of alchemy and mysticism.

So, jig made with register for skirt location, piston pulled down to jig, jig mounted on milling attachment, boring head fitted...



Getting closer to taking the 0.45mm out of the front exhaust pocket and 0.55mm out of the rear exhaust pocket.

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08 Specialized Langster

Cool how are you holding the piston? Are you using the gudgeon pin?

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Buell S1
Buell S3 (Topless for now)
Buell XB12S
Piaggio X8 400ie
Yamaha XTZ750 Super Tenere (x2)
Suzuki GSXR750WR
BSA B441VS
FJR1300

Yes, there is a picture earlier in the thread of the joint, which is pulled back to the plate by an M8 Allen screw through a counterbored hole...

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08 Specialized Langster

So, the joint has a hole for the wrist pin and an M8 tapped hole to pull it back against the jig...


...which has a counterbored hole for an Allen screw...


...and holes for the bolts for the milling attachment...

The milling attachment was set at the right angle for the pockets, set using a dial test indicator, and the boring head set to follow the pocket already cut, then I took cuts of 0.1mm down to the required depth...


...then tided up the fillets and edges with the Dremel, washed them off in the grease eater and then blew them dry with the air line...

Now I can get back to building the engine again...

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08 Specialized Langster

Son of Grenade is all about recycling bits and pieces. SoG will be wearing a set of XB lightning handlebars, which are a little lower than the S1 bars.

I was hoping to be able to use the Domino switchgear which was standard on the S1 and S1w, however the left hand switchgear locating hole in the XB Lightning bars is in the wrong position. Luckily I had a set of unloved M2/X1 switchgear, and here is where the party starts...

Somewhere in the life of this switchgear, the owner had decided to break the locating peg off on both sides.



Perhaps he (or she) had fitted some aftermarket bars, without holes, however I find this switchgear does not give great results on smooth bars without the pegs, rotating easily when using the horn furiously. The screws screw into the plastic moulding rather than a nut or threaded metal insert and as a result do offer much force to clamp. I have seen people use insulation tape on the bar first before fitting the switchgear. The previous owner of this switchgear probably didn't have issues as from the state of the switchgear it looks like it was glued to the grip

So, I went in my screw box and pulled out some M3 allen screws, and machined the heads down to 4.8mm diameter and the thread down to 2mm...



This allows the new peg to be pushed into the hole which slows through the original peg into the moulding and no glue needed...



Switchgear now locates on the bar...

Of course, I could have junked this switchgear and bought some more of the Bay, but with spares running out, I am all for make-do-and-mend...

I bet Willybuell is proud of me...

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08 Specialized Langster

I know that I am. Nice work.

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I started out with nothing and still got most of it left.

Is it going into a hardtail bobber frame ?