i have read this threrad today ..........and this is so late........you started it in 2010.......how can i miss this ........................

i always think in similar direction........if i can't afford it ...........why not build it..............

i will give my suggestions in next post.............btw i am an electrical engineer, i have done my PG (M.E.) from VJTI, mumbai, right now i m in pune, aamby valley city, lonavala............always wanted to join auto industry but heck....i am here designing power systems for cities....

with some help from other friends over here on xbhp, i have converted my pulsar's AC electrical system to DC.

i might come in handy ..........while designing electrical system....for your bike............

i know autocad also...........if you need anything 2D........i m here.

now let me have a cup of tea and a sutta............will post again....

just saw the video of muskat vtwin..........the guy did an awesome job.............but it also took him nearly 5 years and he had good resources too.

@ rahul

Lets do it buddy, there's enough passion and spark inside us already.
I can help in the electrical department too.

or in whatever department you wish to put me in

just now read the crankshaft link given in one of the posts......nice article and nice website.............guys it is really difficult to design and build engine components...........that is why most of the people who have done it use a maruti 800 or maruti zen engine along with its gearbox as mentioned in one of the links ........in this thread itself.........

i will give you guys an idea of what i used to think.......

actually i am not into cruisers and thumpers, i like fast fully faired, boxer bikes like R1 and all. obviously i can't afford them now..........so i sometimes think if i can build a pulsar 440 using two 220 engines.

now your project is also quite similar but you are going to use bullet engines. now either we can purchase an engine from western countries or build one. purchasing will be costly but reliable.

if we want to build one, we should try to use as many standard parts as possible to reduce cost and increase reliability.

what we can do is use standard bullet 350 or 500 cc engine block, piston, head, camshaft, valves etc and mount it on a crankcase. the critical part here will be the crankshaft. at this stage i don't think we have the knowledge and expertise to design a crankshaft, so either we have to get it done by some professional or use one from some other vehicle. i can suggest one thing here, can we use maruti 800 crankshaft and use 3 instead of 2 engine blocks, make it in-line-3 instead of v-twin. this way we will have a ready made available crankshaft. then we have to modify the crankcase housing. i am not too familiar with bullets coz i am a pulsarmaniac. but i think basics should be the same. so we cut open the crankcase housing and we have to extend the width of crankcase housing to approximately 3 times and modify the end pieces to fix the crankshaft with bearings. in this process we may have to cast crankcase housing , which can be done (instead of designing and fabricating crankshaft which is too difficult with the available resources in india). once we have done this, gearbox is not a difficult part to deal with as gear wheels can be fabricated. or we can use existing bullet gearbox with some sprocketing to increase the final top end. anyway we don't have roads in india to ride at 150+ speeds and existing bullet gearbox does well at speeds like 120 kmph so i don't think it will fall apart in increased 30 kmph. so we will have a bike which accelerates much faster due to double or triple torque figures and with top speed of say 150-160 kmph, i think that should suffice. as far as cooling is concerned we can let it be air cooled or make it water cooled. we will add a small radiator and connect it to copper tubes which will encircle engine blocks, as far as electricals are concerned we may have to design and fabricate a stator plate of modify the existing one, in either case - it can have two seperate ignition coils.

well guys, i have suggested a way to do it ......only difference is that instead of a 700cc or 1000cc v-twin, it will be a 1050cc or 1500cc in-line-three.

this was just a suggestion......think about it. now i am going to sleep its already 4.10 am. i have to go to office tommorrow or rather today, as its already morning now.

btw, i am also in pune, so you can PM me you number and we can get in touch. also tell us do you already have a bullet?

will check for your replies in office

i am editing this post----we can also use RD350's crankshaft.

i am in office and editing it again--my way of building engine will change the sound of engine, it might not be a loud slow thumping sound.

Designing the crankshaft is easy, manufacturing it is a pain. I suggest you instead pick up an existing V crank, con rods, pistons, rings from the used market.

@ prince
i know u. u r amby valley guy ! that road to "El-de-Rado" i will never forget.
thanx for u r suggestion, all for Maruti engine and in-line 3 concept.
two parts to answer.
1. we hv given the tough for maruti engine and i meet two guys done that, the real problem in that is heat (temperature) management. if we done that then we hv to go for the gearbox and its assembly. even if we fix it, the RTO will not allow us on the road (i hv gone through the AIAR.) and costing goes high too, now is there any other facet that i missed ?
2. second part is we are building 700 cc V-twin power engine, all together. but we must began with crank case and shaft. well now cruise and Boxer that depends up on the design of bike (except engine). we can use same engine for sport bike that will like stream line butterfly and top speed of 180 kmph. (100 mph). for reference "yamaha MT 01" ( plz yamaha is only reference and not bench mark.)


for the time being i got the basic on the paper and hv to convert it in softcopy, to the max we are using std royal enfield parts.

1) i am not saying to use maruti engine, just the crankshaft. but now i think its better to use RD350 crankshaft, this way we will have a standard crankshaft which will be available off the shelf. will save the effort to design and manufacture one. only difference is it will be an inline -2 like RD350 instead of V-twin.

2) one more thing i want to ask, do you own a bullet, because i have a pulsar and know it inside out but my knowledge of other bikes are limited. same way if we have bullet rider or mechanic in our development group, it will be helpfull, otherwise we have tofirst study the bullet. anyway since we are building a bullet based thumper, we have to purchase a bullet.

lets meet someday in pune.

@hemank: designing a crankshaft is not very easy, kindly refer the link given in earlier pages.

rahul, i with you 100%.....and if we succed in doing this, you have to help me then build a pulsar 440

i have a suggestion, JOEL is a man who does some serious mods and that too without compromising the reliability of bike too much, i think we can discuss this with him as well. i am sure he can throw in some light.

chalk out a detailed plan and tell us rahul. we are together in this.....

first a bullet 1000cc then a pulsar 440 cc........BLOODY HELL....., I AM LOVING IT.

yea the idea is the same wat u think in u r heart.
guys like bikes bet'n 450 cc to 800 cc cause its fast and safe for Indian roads.
@ prince i got bullet and m using it since long back. in fact i service my won bike on every week end and do some experiments too ( she don't mind me doing experiments ).
we hv purposefully chose the RE and the act to redesign the crank case. one we don't need to bother about the clutch box and primary drive second we hv a ready made gear box. and rest of the assembly. (there are three separate parts in a RE. this is not UCI like pulser or new bullet. 1. gear box 2. clutch box and 3. crank case.)
now we can reduce cost and time by using clutch and gear box from the stalk, but we hv to redesign the crank case all together.

nice.........so tell me whts the plan..........prepare a schedule and tell us what help you need from us.

hey prince tell me wat u can do with the CAD ? and at wat extent u can go ? just for basic design ?

I thought that the bike would be ready by now. With 700cc V-Twin churning out atleast 50bhp.

I am surprised that still its in planning phase.

Probably by 2015 planning phase should be over I guess. or may be 2020.

If V-twins were so easy.. Bajaj would not have struggled for 10 years to get the refinements to this decent level.. in current generation pulsars. And pulsars are still single cylinder. And still bajaj is nowhere near to Honda in refinement levels.... With hundred of engineers working in best labs.

Bottomline - Impractical project. You cant make a V-twin which will perform for more than even 5000 kms in flawless condition... without failing.. beat that... so called OPEN SOURCE ENGINE DESIGN PROJECT... The plan itself is not going to work.

Rahul get your knowledge right. You cant make an engine this way. Else every tom dick and harry will start making engines. Its not a Mobile Application.. that you have SDK.. and start writing codes for new application.

Those are some serious words of wisdom from Mr EINSTEIN himself...

We have a name for this: it's called "The crab mentality". If mr Bajaj decides not to manufacture a v-twin in India it;s not because they all are engineering college dropouts.. It's because they have people like you in mind who need 150 kmpl from their mopeds....

Well said about the SDK... This proves my doubts that you have to be in IT to be so hopeless in life... These guys are at least trying to do something and are passionate about it... Let them be...

For you, I have an advice!!!! There is something called the internet. Type Google, search "can I EVER do something in life"... Result: you gotta be kidding me ....

Anyone got an update on this?
i wonder how come an attempt like this got no attention over the whole web?? Even the participants in this thread never cared get details !!

Please some b'lore guys track down this 'Sardar'.
full post #20 here: http://www.xbhp.com/talkies/471289-post20.html

its good to see this thread alive once again, but no updates, no real work done....

rahulingle1 where are you man.

1-2 years passed. Where is that 700cc monster ?