Merlin DOHC 8 valve

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I've pressed the go button and took the patterns i got from Merlin to the pattern makers that Merlin use for them to give them the once over and get cast for me in LM25.
They (the pattern makers) were very helpful and had worked on some very interesting projects. They had made over forty patterns for the cycle/carbs parts for the Six cylinder Honda replicas. Manx norton cylinder heads, racing carburetors, fork legs sliders for norton forks (the pattern is up there on one of those shelves, they said), dunstall alloy barrels ( also on the shelf somewhere) etc etc.
When i told them the tale of how i came by the merlin patterns and drawings, one of the owners toddled off into a corner of the workshop and came back with a couple of very grubby cylinder heads. My next reaction was to exclaim 'you dont have the pattern for these do you?' 'No' was the answer. For some reason they never got the pattern done, ( cost presumably) the standard head is quite a complex casting, involving a lot of cores etc (I repeat what i said earlier, the Fullauto head is very good value for the money)
Apart from the JAP engine castings that they hold the patterns for, they also had a pile of G45 Matchless heads and barrels that they had cast, in a pile in the corner, presumably awaiting someone to buy them.
All in all a very interesting couple of hours chatting mostly about the classic bike scene and how much bullshit is talked and the lack of credit given when someone says ' I've built this' and the excuses given when they were having to chase money owed for work done.
I've yet to make a start on drawing the head up in Autocad. Got the current project to finish first.
Regards
Peter
 
Outstanding. Looking forward to following your progress.

Ken
 
I've pressed the go button and took the patterns i got from Merlin to the pattern makers that Merlin use for them to give them the once over and get cast for me in LM25.
Regards
Peter

Exciting times Peter, good luck with your project
 
How many parts get cast, head and covers? Is more than one set getting cast since they got the cores out? With all the talk here of smaller ports for high velocity and big inside radius behind the seat i'd be inclined to leave some extra material to work with. I'm sure the guru's here will have some suggestions when you get some fresh drawings.

Cool choice for a project!
 
How many parts get cast, head and covers? Is more than one set getting cast since they got the cores out? With all the talk here of smaller ports for high velocity and big inside radius behind the seat i'd be inclined to leave some extra material to work with. I'm sure the guru's here will have some suggestions when you get some fresh drawings.

Cool choice for a project!

How many cast parts? Three. The head itself and two cam carriers (cam boxes) They are simple patterns, no cores at all so a lot of machining needed just to remove metal to get the basic shape. It is a compete blank canvas so to speak regarding port shape/sizes. my impression from the drawings is that they are quite small and have a somewhat downdraught angle.
I have bought a few books on cylinder head porting, camshafts, tuning etc etc to glean as much info as possible before putting the casting to the miller and the Poly quad porting developed by Dave Vizard looks very tempting as it will be a zero cost option (compared to the usual four valve layout)
A question for the engine gurus. Merlin used aluminium bronze for the valve seats back in 1980. Will this still be ok to use with the unleaded petrol we now have to contend with? or do i have to use steel seats and if so what grade?
regards
Peter
 
My layman’s understanding is that valve seat recession is caused by the steel seats micro welding to the steel valves. Therefore, a bronze alloy of some kind is preferred.
 
My brother and I bought a Lotus Europa a couple years ago. First thing I did was find a copy of David Vizard how to tune your twin cam motor.

When I search craigslist its for bikes and parts then machine tools. Folks are selling stuff at scrap weight prices to keep machines alive. For some reason I search for cam grinding machine even though I've never used or needed one. I guess I'm trying to keep my future project options open.
 
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