I did some work on the project! To make the Derbi cylinder fit I had to change the stud bolt pattern of the engine. For the Derbi cylinder to fit it had to be 56×56 mm. Originally the pattern is 54x54mm, so it is only a small difference butt it had to be done.
First I did bore the original M7 stub bolt holes to 8,5mm, so that I could cut M10 threat in them. after that I made some aluminum threatened studs to screw in these holes. For the fixation of the bolts I used Loctite 3450, this way I am sure the won’t come loose. After this I had to let the epoxy harden before I could start milling. When the loctite was hard enough I placed the engine in the milling machine. before I could mill anything I had to make sure that the facing was exactly levelled. Now I could start milling. I began with searching the center of the bore, this was my zero point. From there I started bij using a flathead mill to cut of little as possible layer of the engine. The aluminium studs are now nicely levelled with casing.
The next step is to bore the new holes for the cylinder studs bolts at the exact location. The mill I use has a digital measuring system, so that makes the job easier and accurate. The holes have the same depth as the original ones, and have the same M7 threat. Only difference now is that they are further apart. The last step in this progress is cutting the new threat, after that we’re al done!
Next step for the engine would be designing an adapter to place the engine at the right height and reducing the bore. Next time more about that!