The two rocker arms were mostly done using the CNC, first roughing out the profile and contour and then using a corner radius cutter to refine the shape before drilling the pivot hole. After that they were sawn off the parent bar and held in some shaped aluminium jaws to shape the other side.
The adjuster and oil holes were done on the manual mill, pivot hole reamed and some final needle file work soon had the contours blended in.
The rocker post started as a simple turned part.
Which was the milled and reamed before a bit more shaping was carried out.
The valves are fairly straightforward turning from stainless steel using the tailstock support to prevent the 3mm shank deflecting. The DCGT tip helps with this and also allows you to get in close to the revolving centre.
A 0.7mm carbide grooving insert was used to cut the groove for the spring retainer. After sawing off the main bar the head was faced to final thickness then the valve inserted into the collet from the back end so that the centre hole could be turned off and the end slightly domed.
The cam blanks were turned from silver steel (drill rod) before making use of the CNC to cut the profile, so much easier than having to use a rotary table and keep adjusting the mill to a set of co-ordinates from the likes of Cam-Calc
After heat treating they were Loctited onto the 5mm shaft, I just used the indexer and a square to set the angles as the indexer was already on the mill.
The piston was turned from some 1"dia 6082 aluminium and a groove cut for a single Viton O-ring.
I did all the hollowing out on the KX3 which was a lot easier and quicker at doing the ‘dogbone’ shape than using the rotary table.
It was then just a case of cross drilling and reaming for the wrist pin before parting off and skimming the top.
Part one here Part two Part three Part four Part five Part six Part seven
