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Replicating The North London Garage 1909 J. A. P. Engined Record Holder, Part VI

Pavel Malanik has been a very busy man engineering and machining the remaining components for the power plant that will be installed in his 1909 J. A. P. Engined Record Holder recreation since we last visited with him. In Part VI, we have many more construction photos and images of both sides of the completed 165.62 cubic inch (2,714 c.c.) engine.

The timing side of the finished product can be seen above with the drive side can be seen at the bottom of this post. You can follow the machining process of most of the remaining pieces needed to finish off the inside of the engine along with the rocker arms, pushrods and exhaust stacks here in this post.

  • L to R : Alloy steel being roughed out in the lathe for one of the camshafts. Milling operations to shape the cam lobes. Final finishing of the nose of the cams.

  • L to R : The finished camshafts, drive gears and cam followers. Finish milling of the inside of the timing cover that was machined from a solid block. Exterior of the timing cover.

  • L to R : The crankpin half of the flywheel after lightening. The inside of the only non-original type piece on the engine, a clutch that is inserted in the original style drive pulley for safety reasons and easier starting.
  • L to R : Partially machined pieces for the rocker arms and pushrods. The completed rocker arm and pushrod assemblies.

  • L to R : The rear cylinder. Fabricated exhaust stub assemblies and the front cylinder.

Below we see the drive side of this beautifully crafted engine awaiting it’s intake manifold, carburetor, ignition system and a few more details. After Pavel Malanik is finished with the engine, he will start on fabricating the rest of the machine. Check back soon as it has been a very interesting project that we are following through from start to the finish. You can also view the entire series here from the beginning. You can also find over 50 pages of  vintage motorcycle photos here.

10 responses to “Replicating The North London Garage 1909 J. A. P. Engined Record Holder, Part VI

  1. The construction of this enormous replica JAP V twin is a credit to Pavel Malanik. The work is first class. I restored an 1150 Brough Superior some years back but making an engine like this one is a whole new ball game.
    I would like to be there when it fires up. Good luck with the rest of the project.

  2. If I may be permitted, I have two questions.

    1. How was the `floor’ of the inside of the timing cover machined? With the tooling marks all so perfectly concentric, how were all of the bosses for the various raised features apparently skipped right over?

    2. How were the cylinder sleeves installed in the barrels? My familiarity with this process involves heating one component and freezing the other to change the respective diameters and allow the sleeve to be pressed in with the fit secured by normalizing temperatures.

    • Kevin, Most of the area was milled with the use of a rotary table as you can see under in Part II:

      I am not certain how Pavel installed the sleeves in his cylinders. I usually do it with a press fit which is a common way of doing it. If there is not a lip up at the top or a head to keep it from moving up or lip at the bottom to keep it from ever moving down if something goes seriously wrong later on, pins can be installed thru the cylinder and sleeve to retain it.

  3. Thank you David. My first question primarily was aimed at the center photo of the second row of pictures above. I find it intriguing that the tool cutting the grooved floor is able to skip over the areas that became bolt bosses.

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