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November 16th, 2017, 07:56 PM   #1
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104mm piston group buy??

Hello mates. I'm in process of organizing total rebuild and major upgrade at the same time to 2005 Husaberg 650 engine. I'll have Travis do all the work for me. While doing so much work I've decided to go for 104mm big bore kit. However pistons are a bit of a problem. $300 ea and minimum 4 to order. I want stock compression for extra long engine longevity. I'll have plenty of power with big bore, ported head and extra large 33/38mm valves? Ported mikuni carb to about51mm. Whole engine will be micro blue done. Both mains 20mm spherical rollers. On top of that I'll have about 3l of synthetic engine oil. My goal is to maximize both longevity and breathing/capacity. To get very good usable power and 1000 engine hours before next major repair. Which would be really never again. Might be getting carillo conrod too. This would decrease reciprocating mass. This engine will replace my 2007 Fs 550. And now my question is, anyone up for 104mm piston?
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November 16th, 2017, 08:00 PM   #2
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Forgot to add that this piston will be original clone give or take except diameter and also has some fancy coating on it. Diamond? Ceramic? Cp piston? If I remember correctly. Travis is using really good stuff.
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November 17th, 2017, 12:09 AM   #3
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Sounds good ask for same piston height as the oem elko. Then squish is same as head gasket thickness . So Comp ratio about 11.8 with 1.2mm squish. Then we can increase cr and reduce squish if needed.

I'll take one but can we do it in 104.8mm be good if it comes from Je or cp. Fwiw I don't need coatings.

See diy 700 kit for 3D piston tops with valve pockets and correct volumes etc
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November 17th, 2017, 03:13 AM   #4
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I am sure I was told that DCR in the UK have some big bore piston from JBS ...might be worth give them a call
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November 17th, 2017, 08:15 AM   #5
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I have a '95 vintage 501 that needs a rebuild and I was thinking of using the same piston that I'm using for my 660 build...but...this sounds interesting.

With 70.1mm of stroke and a 104mm piston, I'd be looking at a "short" stroke 595cc engine. With a 104.8mm piston it grows to 605cc. Me likey! I wonder if there's enough water jacket left after that much sleeve is pressed in. Might have to talk to Travis about this.
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November 17th, 2017, 08:48 AM   #6
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Originally Posted by paolo6 View Post
I am sure I was told that DCR in the UK have some big bore piston from JBS ...might be worth give them a call
Sent e-mail question there. Probably not doable because of added cost of shipping over the piond. But we'll sče.
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November 17th, 2017, 10:00 AM   #7
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Originally Posted by bushmechanic View Post
Sounds good ask for same piston height as the oem elko. Then squish is same as head gasket thickness . So Comp ratio about 11.8 with 1.2mm squish. Then we can increase cr and reduce squish if needed.

I'll take one but can we do it in 104.8mm be good if it comes from Je or cp. Fwiw I don't need coatings.

See diy 700 kit for 3D piston tops with valve pockets and correct volumes etc
I've been talking to someone racing sidecars. Possibly Dim Werks and they use 104mm this is maximum diameter without boring cases. This would be my goal as well. Save cost on machining. Easier job overall for all interested doing it themselves.Dr.C is using 104 too.
Other dimensions as deck height and squish I just don't know these details. Fine with me if it can be just dropped in without any further mods required. I'll re-read your posts tonight. Perhaps its good way to go.
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November 17th, 2017, 11:17 PM   #8
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105mm still doesn't require case boring. I have 104.95 liner

The trade off is that there isn't much material left in the liner to machine grooves for orings
I never used orings just very good silicone
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November 18th, 2017, 04:15 AM   #9
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Originally Posted by bushmechanic View Post
105mm still doesn't require case boring. I have 104.95 liner

The trade off is that there isn't much material left in the liner to machine grooves for orings
I never used orings just very good silicone
Interesting that you still didn't need case boring with such large diameter. I'll take this information and go over it with Travis and see what he says about head gasket issue. How long do you run with silicone without any problems? 1,2 years? And how many engine hours approximately? As you see I'm attempting to design and build it to last 1000 engine hours and dacades long in time. Travis said good things about you Bushie, he remembers you.
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November 18th, 2017, 09:34 PM   #10
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About 120 hours max

But imho it could be indefinite.

my problem with paddle tyres is The tiny little gears keep breaking lol maybe I should put silicone on them too

You need to degrease with detergent and create a large bead of silicone above the usual sealing surfaces

It's messy and not many people would use enough I think.

But I'll stand up in court and swear it works very very well with three bond 1207b at $60 a tube it bloody should.

Head gasket issue is more difficult you'll probably have to make a hybrid fibre / copper one the same design as I use with a solid copper fire ring and a wire ring on top of the liner and use high tension arp studs
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Last edited by bushmechanic; November 21st, 2017 at 01:40 AM.
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