CR500 conversion

[ludedude]

See some pictures of Paul's CR500 conversion progress here

http://www.45thparallel.net/coppermine_dir/thumbnails.php?album=23

So do you have to move the bolt holes for the cylinder studs? Can't really tell FROM the picture, I heard you have to as they sit farther back...

[PJ ENGINEERING (PROX)]

More photos of my pilot CR500 convershion this is where i bored out the CR500 cylinder to take the plugs


These are the plugs i have made to go INTO the holes FROM the top


Here are the plugs put in



Here you can see i have put a 45 deg chamfer in the hole and on the plug and welded them at the base and i will skim them flat.
 

and this is my pilot being striped down for full restoration.

 

[ludedude]

so you're changing the hole locations on the cylinder! Hmmmm

ATVR/PCP/Jay relocate the studs on the cases I'm quite sure....neato...fresh eyes, new way of thinking...

This will give you enough room (the plugs) to relocate holes to match the 400 studs? If so then it's just a matter of opening the cases up for the larger jug? Oh yea, and making the top of the cases wider, for the increased size of the jug....and turning the clutch, and grinding the starter, and making an intake.....

You need a 500 pipe for that? I can get one FROM Power Pros for ya and add it to the pallet of parts!

[PJ ENGINEERING (PROX)]

This is the pipe i have don't know what it is Hoser said he thought he did but i have forgot what it is



this is the std pilot carb and the one i will be fitting



and i thought i would SHOW you my 2 cars


A bit difrent to your kind of cars i think :?

"Why i have moved the holes in the Jug" I canot see how you can plug the holes up in the case very well and the way i have done it the jug gets clamped down useing the plugs so there is no way for them to let the jug move.

I can't see how you can weld the holes up in the case you would only fill the top 5mm or so and i would think the stud may pull out ? any one got any photos of the
ATVR/PCP/Jay convershion :?:

[ludedude]

Neither of those are a standard pilot carb....they're both flatsides...standard carb on the pilot is a Keihn PE34 I believe

The pipe is a Power Pros Torque pipe...but probably for a 400, not a 500.....The 500 is larger I assume, for more flow...

I like your idea of the plugs on the cylinder...I think there has been issues with the CR500 conversion letting go FROM the cases. ANd maybe why they LIMIT the horsepower...should be able to get more than 72hp FROM a CR500....don't you think?

So when you ready to do mine? :wink:

[PJ ENGINEERING (PROX)]

Hi Brian, can you get me a price on the 500 pipe then and any info on it ??
Thanks

Paul

[ludedude]

Will do...ship to Oregon to your buddy?

[PJ ENGINEERING (PROX)]

Yes please :lol:

[twostrokes4ever]

so how powerful r those 500 pilots i know the regular stock pilot is fast already, thing probably hauls with the 500 kit :shock:

[ludedude]

Do any more work to the CR500 lately Paul?

[PJ ENGINEERING (PROX)]

no not yet been to bussy with moving work shops to do any thing. I wil post new photos when i have

[350nut]

no not yet been to bussy with moving work shops to do any thing. I wil post new photos when i have

Please send them, I would love to see them as well.

[atvnut]

Are you moved yet LOL c'mon we are waiting lol

[PJ ENGINEERING (PROX)]

I have done some more work today on the alloy sleeve. i will let the photos do the talking.

 

[pilotdude]

How much horsepower you expecting to get out your 500 cylinder? You going to do some custom porting work? I heard the you can get 90 h.p out of the 400, if you stroke the crank, replace the lining with aluminum and with a nicasil coating, porting, and a new head design. What you say 100h.p out of the 500 acheviable?

PD