.

490 dia

flat to fit oil pump .250 dia.

.562 .625 .625

1.812

3.875

Camshaft 112301 Drawn by Glen Bond

Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.2.16 system
 TDC

90 270
0
rotation
45 315

BDC 180 90 270 180 BDC

135 225

180
270 90

This is the Saito timing TDC

Saito FA200Ti cam timing:
opens closes
intake : 40 btdc 60 abdc
exhaust : 75 bbdc 25 atdc
65 deg. overlap
Saito Cam Lobe Timing
Intake Lobe on Cam
View from front of camshaft
Exaust Lobe on Cam
BECO 2.0 Cam. lobe timing
73003 Drawn by Glen Bond
Drawn with XFig 3.1.4 protocol: 3.1 on a Linux 2.0.3 system
 Oil
Channel
Front
Rear
2.675"
Top View
3.100" Front

1 3/8" Left Side View

Oil Channel
Oil Channel

1.25
0 ra
dius
left rear
right side front
side ius
/8 rad
11

Right Side View

Front View

Crankcase Left Half 9300 Drawn by Glen Bond

Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
 Crankcase
Back cover 3.625

Front cover

prop washer

Propellor

Propellor base





















spacer

Oring seal on shaft Oil pan roller bearing

Timing gears
Oil pump double sealed

Details of prop end of crankshaft May 15 2002 Drawn by Glen Bond

Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
 Step by step directions for making a rod
Material: 6061 aluminum, 1/4" thick

1 Cut a blank 0.75 wide by 3 inches long from 0.250 thick plate.
Mount the blank in the mill vise vertical.
.2500 dia. .435 dia. 2 drill 2 holes for the rod cap screws 3/4 inch deep.
Countersink .100" with a 3/16 endmill.
3 cut the cap off from the rod.
4 mill the ends of the rod and cap flat and SQUARE!
Hollow out 0.080 deep (this step is not necessary if the cap is cut accurately.)
with 1/4" ball end mill 5 size cap to 0.360" and tap threads (440) in the rod.
6 drill out the rod cap for screw clearence (7/64).
0.325" 7 attach rod cap to rod blank and mount flat in the mill.
8 drill and ream the hole for the big end.
9 drill and ream the hole for the small end.
1.850 10 drill the holes for the sholder radius, use a 1/2" endmill.
drill 1/2" 11 cut (using an end mill) the straight sides.
12 put the rod on the rotary table and round the small end.

0.500"

Cut at this line to seperate 0.360"

the rod and cap

0.4062 dia.
(13/32") countersink screw 0.100"
0.740"
rod cap screws
440 0.100"

0.540"
This drawing not drawn to scale
Connecting Rod 111001 last updated 11Dec05 Drawn by Glen Bond
Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.4.26 system
 0.300" 0.355" 0.300"

0.275" 0.275" 0.275" 0.275"

1.600" 3.350"

0.690" 0.400"
0.750"

X
0.550"

1.475"
0.550" 0.737" radius
X
0.373" Dia.
0.375" Dia.
0.500"
0.375" Dia.
0.0937" dia. 0.100" deep
Oil passages 0.4375" Dia.
Use # 55 drill (0.052")

Crank shaft is turned from 3/4 X 11/2 HRS flat bar

Turn crank journals first, then main shaft and journals.
Put bolts at X while turning main shaft to hold from flexing.
Crankshaft Stroke = 1.100
Use with a bore of 1.100 to get a 2 cubic inch engine
Crankshaft 9200 Updated 1106 Drawn by Glen Bond
Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
 0.125 drill through for valve stem
raised 0.050" to fit inside valve spring

Cylinder head is made from 2.5" 6061 aluminum bar stock

Cooling fins are evenly spaced. Cut with 1/16" wide cutter.
Spark plug threads are 1/432

1.000 Note: Make left and right side heads

intake to rear, exhaust to front.

ex. valve dia: 0.488 Port bore: 0.438

outside dia. same as in. valve dia: 0.550 Port bore 0.500
valve dia + 0.015

Bore to same as port bore Spark plug hole

Valve Guide detail 0.050

Bore through for valve guide

Raised .040

0.275

0.900 0.550 0.925

1.000

2.375

Cylinder head with dimensions Drawn by Glen Bond Feb. 15, 2002
update: 6504 Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
 0.625

0.440

1.700

Match to crankcase

Thick section for lifter guides. lifter guide

0.335
0.320

256 screws

0.150 thick flange

0.055 thick flange
3.140

Oil Pan 11900 All dimensions are inches unless noted. Drawn by Glen Bond
Drawn with XFig 3.2 protocol: 3.2 on a Linux 2.2.13 system
 Piston Dia. 1.096"

Wrist Pin Bore Dia. 0.250"

Oil holes
16 holes (more is better)
0.040"
approx 0.028"
Size to fit rings 0.120"
0.175"

0.056" 0.330"
0.470"
0.625"
0.750"

0.990"
0.125 radius

0.330"

0.745"
Make sure this is deep
enough for the oil holes
to drain into.
0.900"

This drawing is 2X size

Piston for BECO 2.0 Updated 11Dec2005 Drawn by Glen Bond 1MAR02
Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.2.16 system
 Actual size

Drill 1/8"

0.090"
0.188"
0.310"

0.975" 0.650"

1.625"

Drill and tap for 256 screw

0.125"
1.875" Drawn 2X Size

Rocker Arm for BECO 2.0 Drawn and Copyright by Glen Bond 1103
Revised 7703 Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.2.16 system
0.092 dia. 0.125 dia. 0.550 dia. intake
0.488 dia. ex.

0.110

0.050

Spring cap approx. 12X size

0.060

1.660"

Intake valve Drawn 2X Size

0.315 0.240
0.125

Use 60 degree
center drill

0.080

0.150

Valve and Spring cap All dimensions in inches Drawn by Glen Bond 32602
Revised 7703 Drawn with XFig 3.2.3 protocol: 3.2 on a Linux 2.2.16 system