Here's the disc valve cover modified to take a 20mm carb
The 20mm tube sits right against the edge meaning that leaving a decent amount for the disc valve to seal would leave a nasty step in the inlet tract so after a bit of thought I migged up the top area and reshaped it with the die grinder to angle slightly downwards and widened the hole out to the D shape you can see here.I have since this pic was taken eliminated the slight hollow at the top, dont think it would have caused a problem but just in case.
Here shows the relatively smooth flow I've got now, I relented in the end and had the case re-welded and reworked the intake to leave 2mm for the disc valve to seal I also has a bead of weld run along the bottom of the opening and reshaped it to flow the gases over the crank it means the inlet flow is directed up and down a touch but eliminates any obstructions until it's inside the crankcase.
At last my kickstart arrived today....hurrahhhhh!!!!!!! just in time for lunch so I got straight on to heating and bending it so it no longer resembles any other ER50 kickstart. Got carried away and didn't take a before shot but it certainly didn't look like this!
Trial fit after final bending
Clears the brake pedal and foot rest a treat now, I'm really glad to have got this sorted, at one point I was beginning to think it would be bump start only, it's very short but I reckon it will spin the engine over ok.
Due to the mods to the cases leaving them bare alloy isn't really an option so I cleaned them up and gave them a coat of silver and laquered it, didnt come up too bad at all in the end
Just before I left for home tonight I stripped out the donor engine, will hopefully get to build it into the new cases tomorrow.
Not much time today, but did manage to bore out the casing and mock up the carb on the new stub, no way thats going inside a standard casing The sliced carb cover came with the donor engine.
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The sliced carb cover came with the donor engine.
