When something like an engine is being built, each and every part has a measurement. One needs detailed radiuses and curvatures for engine making. It is not so easy.

Definitely need a Catia user here.

we will measure each and every component of the engine, but in the end we will not use the all the components in the new engine, all we are using is the timing gears and rockers, mod push rods and oil pump.
the entire crank case has to build a new. we know it is not easy but still not imposible too.
do u want me to right complete idea ? i can right it wat parts to be used and which to be created new, just waiting for some photos and measurements so that we can name the parts to avaoid the confussion. my article is ready to post here about the new designe. satya tell me wat u want me to do ?

I HAVE A CATIA DESIGNER !!!!!

all he needs is an RE cad, he's an automobile engineer and he knows a lot about it then US.

provide an oem RE CAD as soon as possible.

@ rahul

dude, photos itself won't help, even if they are with measurements.
we need a CAD of RE man.

after designing, we'll get the thing FORGED.
even those forging people need a 3D design, preferably CATIA design, that's it.

we manage a man from Ah-bad he is doing cad 3d for avl engine.
from 2 maro i will go to the shop and get some engine componets measured, then we need to name them and post to the Gujrat. the boys name is kartik "GAS" on xbhp
he will also go out for local machanics and shops for measurements. i want u to do same. soon i will post the procedure to photo and measures once i discus it wit kartik. hope every thing will go fast and cording to plan. we are running 5 day behind the schedual. need to work fast.

hi frns,, this is kartik from baroda (gujarat)
i've read the discussion n seems like everything is goin perfectly,,
before is go further i wanted to tell u something about myself that i m not an automobile engg,,,,i m a commerce graduate n biking is my hobby n i want to turn it into my profession,,,, n i m sure anything can be build in our country...

even i m working on similar kind of project,,but earlier people suggested me to go for 2strok vtwin engine, so i bought a luna's engine n started working on it.
but my main interest is in 4strok type...n its easy for me to make drawings in autocad 2d and 3d....
Rahul before u go for actual fabrication,,,just try to know some industrial process,so that it would be easy for u to make engine parts,,, like u cant cast a piston,,,its to be forged,,,,same in connecting rod n crankshaft too,,,n if u dont know about industrial process then u will end up with lots of expenditure with little work done.....so be aware of this,,,

well for ur engine purpose i'll try to get to some auto shop in order to take measurement of required parts n if anyone of u have those parts or their dimension then please send it us,,,so that we can make final drawing out of it,,,,

i m posting some pictures of my chopper that i built a year back,,i used YAHAMA RX100 engine to power it...hope u all enjoy them,,,

welcome to the party mate. this is wat we need inspiration and here we go, we will try to search the industrial process and we will select the best and economic for our project. i m tryin to measure the engine componentas too. i hope soon we can find the plethora of info here. thanx to belive in us & u r welcome again.

some engine components.

guys here are some pic i hope our designers will finnd it helpful. we are still tryin to get orthographic pic. but for now, these for the bacis idea.

some engine components.

here we go again, sorry for not getting the measurements but i think in long run this will also help us.

Regarding connecting rod n crankshaft!!

HEY RAHUL,,,
TILL NOW U HAVE DECIDED TO USE A ROYAL ENFIELD'S PISTON,CYLINDER AND HEAD, BUT I WONDER WHAT TYPE OF CONNECTING ROD AND CRANKSHAFT R U GOIN TO USE IT?
LIKE IN HARLEY U WILL FIND THE CONNECTING ROD ARE PLACED INSIDE ONE ANOTHER SHARING THE SAME AXIS OF PISTON MOMENT. LIKE I HAVE SHOWN IN THE FIRST 3 PICTURES,,,,WHERE AS THERE ARE ENGINES IN WHICH CONNECTING RODS R PLACED SIDE BY SIDE LIKE SHOWN IN THE LAST 2 PICTURES... SO WHAT KIND OF ASSEMBLY R U GOIN FOR?
IF U GO FOR FIRST TYPE THAN U NEED TO FORGE NEW CONNECTING RODS AND IF U R GOIN FOR ANOTHER TYPE THEN U CAN MANAGE IT WITH ROYAL ENFIELD'S CONNECTING RODS.
I THINK THE SECOND ONE WILL BE BETTER AT THIS STAGE AS IT WOULD SAVE LOTS OF TIME N FINANCE TOO...U JUST HAVE TO WORK OVER CRANKSHAFT AND CRANK BODY,,,

posting some new picture to make u clear regarding what kind of crankshaft we need to design,,,
thats a six inch diameter piston,,,u can make out what power it must be generating??????

u r correct !

this is the right way. i was thinking of same from where to start ? and the right way is from crank shaft. the pic [down] u have added is perfect for us. our crankshaft will be like this. we can't use RE connecting and crankshaft.


We have to forge new crankshaft and connetings like shown in pic. the conneting rods i think upper part where it connets is side the piston head will like RE and other end will like KTM. the stock honda civic V6 engines connecting are also the we want to use, we can use those too. but we hv to mod them. we can get idea by looking those connetings and crankshaft setting.


i have try to explain these in pic hope u can get the idea !
may i know if u have started to make designe ? just make basics and put here so that other how are doubted on this project may know that we are doing it, and to build a new engine is not impossible. thanx kartik.

this is by Alok Das.

he has done his chopper only in the collage, this man can give us the model. for those how want the basic, pry alok and kartik will work out.
i m posting some work by Alok here. i hv ask him for more details lets hope he will contribute.

hey rahul,,,one more question regarding the engine is r we goin to make a separate gear box? just as u must have seen american vtwin,,,those engines have separate gear box connected by a timing belt,,,,,,like motor portion n gear box is 2 different parts n they together form an engine,,,n in indian market we havent came across anything like this,,,all indian 2wheelers have inbuilt gear box,,, so let us know whats ur view regarding gear box.

hey buddy, RE is the same type of engine. cluch box, gear box are separate from the main motor. that is why we are using RE as a base. all we have to do is manufacture a new crankcase and rest we can use the age old RE. now get it ??

bro you may have to get new gears cut, because when you go twin cyls and with proper tuning, your torque output will almost double.

Gears short pad jayega. You can make the final gear ratio taller and keep the gears stock, but that will put additional stresses on the gear box and the bearings, and could lead to premature gearbox failure.

There are few gear manufacturers in the Mumbai region, but most of them are mass manufacturers and will not entertain our cause. See if you can get a workshop with a milling machine. (cnc/nc experienced with gear cutting)