Machining a billet Zundapp engine block part 2

As a new project i want to cnc machine a old Zundapp engine block which no longer be made. To complete the engine block there will be a total of 35kg of aluminium.
The video is made from small clips and pictures recorded with my phone. During the machining and assembly process.

[@klaasbloem]

That must be the best looking and most expensive Zundapp engine ever. Top job Stef!

[@VHERSACNC]

Amazing work. very impressive. The great work you did on your machine build is paying off.

[@Svanitterzon]

Yes im still super happy with it, and its now making me beautiful parts.

[@alexkart9239]

​@@Svanitterzon we want to see all beautiful parts, and other things that you making.

[@TAH1712]

@@Svanitterzon yes, very beautiful parts... they talk about the art of machining - I can see the lovely chip cutting actions and stunning chip cutting in those video slow-mo's. Is the m/c still a 6k max spindle?

[@gertkristensen6451]

best home made cnc ever seen

[@jasonruch3529]

Very impressive! Great job from the USA!

[@eltarb67]

Prachtig wat een stukje vakwerk! en zo gaaf om een nieuw Zündapp blok te zien ontstaan dat waren toch wel super machines.

[@user-ec8ud3rz6u]

My first bike was a Zundap moped in the early 1970's, was a handy little beast, then the new engined bike came out, posigorce etc, made lifeca lot easier. Thanjs for sharing this vid .

[@rose-ey6ct]

As someone with a few of these bikes/engins in my shed, I watched the crankcases appearing in absolute fascination.

[@bobturnbull18]

Where are you located and would you sell any transmission parts ? Thanks Bob

[@billbeare1513]

Someone knows exactly what they are doing !!. Such skill !.🧐🏴󠁧󠁢󠁥󠁮󠁧󠁿

[@raulgoncalves3075]

Thank you very much for publishing the CAD files of the machine. Excellent job!!

[@Svanitterzon]

No problem i hope it can inspire you!

[@Vipe694]

Where did you publish the cad files? Its an awesome machine. Maybe someday I'll build my own.

[@Svanitterzon]

@@Vipe694 grabcad.com/library/epoxy-granite-vertical-cnc-mill-1

[@Vipe694]

@@Svanitterzon Thanks.

[@TheLuckyfreeman]

Where can you get these cad files to build this engine? I might like to buy a brand new running engine like the one in the picture running and everything ready to drop in the bike just don't know who to contact or how to order one

[@Viking380]

Beautiful work !

[@qivarebil2149]

Fantastic work!

[@JohnDoe-es5xh]

"Zündapp" is a shortform of the German word "Zündapparate", which can be translated to ignition apparatus. They also made the "MG3" (Machine Gun) after 1965 beside others and of course sewing machines in Munich.

[@pridonki]

Невероятная красота!

[@ST433]

Ohhh. I would love to get my hands on those cad files for the engine :-) Lovely work Stef, just lovely..

[@Joe-jb1jf]

When you got all the tool , it easy to do it. Good job , i like your program on the CNC machine

[@AragonDubs]

Finest master work my friend. Congratulations!

[@Op1zilla]

very nice Sir, billet anything is sweet, congrats an ggz-🚲💥💨💨🌴🌴🌴🌴🌴🌴🌴

[@Tubben-tools]

Mooi gemaakt Stef. Ik heb zelf 3 zundapps staan en ik vind dit wel erg mooi om te zien👍👍

[@wallieonline]

Great video really like the slow motion. Can’t wait to see this project finished and you driving the Zundapp!

[@bertrandlussier8150]

I've just found you vidéo, its Fan-Tas-Tic!!!

[@ludeboukema4111]

wonderful

[@favoritdmitry6786]

Станок у тебя отличный получился!

[@RotarySMP]

Wow. Nice job.

[@Svanitterzon]

Tnx

[@DasMO0]

Wow this is amazing. Great Job. Im wondering how you did the fittings for the bearings within the tollerances? Ist your machine precise enough to cut that?

[@Cabreiro23]

beautiful 😍😍 !! I can't wait to see him on the way 😉

[@MSCNCArtshop]

The machine looks to going very strong Steff

[@jmt2727]

Zeer mooi project, vakwerk!

[@AsitShouldBe]

you should add a full enclosure, is a great upgrade for any cnc mill! it will become quieter, clean and Safe! bye friend.

[@Svanitterzon]

Yeah i know, its already been designed but still didn't start making it.

[@AsitShouldBe]

@@Svanitterzon nice friend, my advice is to use a thick plexiglass, will be also good for making videos without risk your camera😁, nice mill, you made a very nice job, how much you spent until now on this mill?

[@MacJunior696]

Did i remember seeing a video of yours making your own VMC? Did you just build it to make a 2 stroke engine minus the cylinder? Big respect man, impressive machine

[@Svanitterzon]

Haha, no i didnt only build it for this purpose.

[@than_vg]

Dear Stef, congrats on the amazing work! It must be really satisfying to see this through and see it work! Wondering, however, wouldn't you have way to finish-bore crankshaft bearing bores and gear box shaft bores with the cases closed, i.e. in one setup? Congrats again Thanos

[@Svanitterzon]

The bearing holes and locating pins between the carters have been machined in one setup so im pretty sure the holes are in line more then enough.

[@jakobv8]

Very nice video. You and I have almost identical subscriptions. Or at least the same interests. Cool. Good luck with your project.

[@ericvandomselaar8420]

Very good!!!

[@r_moto4018]

Sick video dude! Which CNC Mill you use in the video?

[@MotoBuilds]

VERY impressive

[@TeslaAtoms]

Nice work!

[@MrRubenoz]

Mooi! gaaf om te zien als dit allemaal lukt voorzie ik een nieuwe productie van ronde 5(bak) voet blokken... Zou een uitkomst zijn gezien het spul steeds schaarser is.

[@Svanitterzon]

Het blok heeft momenteel gelopen en een rondje gereden.

[@TheLuckyfreeman]

Like to know how much the new running engine costs where to get it and if you can get a Rickman Metice frame for it

[@skt2287]

Wunderschön. Schöne Span abfuhr.

[@user-gy3xn2ub4k]

Мечта моя такие станки

[@evaork3746]

Damn nice work👍👍👍

[@grumpyg9350]

Fun to watch 👍👍👍👍👍👏🏻👏🏻

[@shootingsportstransparency7461]

Mooi Stef

[@monej-gaming632]

how much does the cnc machine cost?

[@ABHB666]

Absolutely top notch work you have put in to this! How did you come out with all the measurements? Do you have the original drawings for the Zündapp engine or did you measure it out by your self? And the last question do you sell the cad or give it out?

[@Svanitterzon]

I measured most of the critical dimensions using my cnc mill as a cmm. Rest of the dimensions just with a calipar. Im not want to share the design files because there might be a potential business behind these parts.

[@ABHB666]

@@Svanitterzon Ok I do understand why you want keeping this to yourself, any way thanks for answering back and keep up the good work. ☺

[@jobkneppers]

Stef, super handige Harry! Je maakt prachtig werk! Zou je graag eens ontmoeten. Ik kijk uit naar jouw volgende video's. Hartelijke groet, Job Kneppers

[@Svanitterzon]

Dankjewel, waar kom je vandaan? ik woon omgeving Amsterdam.

[@jobkneppers]

@@Svanitterzon Delft, vlakbij. Ik wil niet alles op internet delen maar als je mijn naam opzoekt ga je mij zo vinden en een emailadres wat ik op dagelijke basis lees. Anders, geen idee hoe dit precies werkt, kan ik je ergens privé bereiken zonder dat iedereen onze contactgegevens wereldwijd ziet? Ik hoor graag en ontmoet je ook graag. Leuk!

[@Svanitterzon]

@@jobkneppers Ik heb een mailtje verstuurd

[@dirtboy896]

How did you create your 3d solid models? 3d scanner?

[@kevinr1604]

Very amazing outcome, hope it workjs well. Whats the name of the machine you were using in the video?

[@Svanitterzon]

Its a home build cnc machine, you can find a video about that on my channel.

[@oldschool1993]

My guess is that there were several test attempts milling out a block of high density particle board or foam before whacking away on those aluminum billets.

[@Svanitterzon]

No just straight from the alloy

[@oldschool1993]

@@Svanitterzon Well, you must have a very sophisticated modelling software to account for all the potential variables in tool clearance etc.

[@Svanitterzon]

@@oldschool1993 just fusion 360 nothing special about as long as the model is right the machine will do what i ask him to do.

[@oldschool1993]

@@Svanitterzon Well, I congratulate you on your skills, I have been watching the Grimsmo knives guy and he has a Kern machine which probably cost 500K and he had problems with the tool or the spindle nose hitting the part on some relatively simple jobs.

[@Svanitterzon]

@@oldschool1993 Yes but he is running 5 axis. Then you need to be more careful, for normal 2d milling as long as the tool sticks out long enough you never get a crash. In the 5 years i am milling now i only hit a part with the holder once because of my tool didn't stick out far enough.

[@simonyap6426]

WOW!!!

[@user-cm6tj2he4b]

Mooi werk Stef!!! Ik werk in de verspaning en wil ook ooit mijn eigen maschine bouwen. Mag ik je daar tzt over benaderen voor tips? Keep up the good work!

[@Svanitterzon]

Dankje, tuurlijk dat mag altijd!

[@jong9718]

Beste Zündapp blok ooit denk ik...

[@saldot79]

Not what I had imagined when I saw your build videos of the CNC. But hey, moped parts, why not? =) You think a billet milled block will be strong enough for the 50cc's? ^^

[@Svanitterzon]

I didn't build that VMC for any particular purpose. I think these billet carters made from 7075 alloy are stronger then those 50 year old cast alloy ones.

[@arnoschmadt2686]

I ot no idea how much work it is to do the programming. is that okay for onky one block?

[@martinda7446]

That is just an amazing effort...I would be tempted to buy one off eBay for $150 though😸. How long has the machining taken so far? What alloy did you use? (Looked like it cut easily/nicely).

[@Svanitterzon]

Its machined from 7075 alloy, my number one choice because its pretty hard it cuts really well. So far i have been working on it for around 8 days excluding the design part.

[@airgunningyup]

the blocks of 7075 cost more than 150 alone , hed need to sell it for closer to 2000 to make aany sense

[@Svanitterzon]

@@airgunningyup haha yes the raw stock material for all 4 parts was around 450 Euro... 35kg of alloy in total. Right now i already cutted away roughly 18kg of material.

[@martinda7446]

@@Svanitterzon It looks beautiful. It should go into a gallery not a bike.

[@martinda7446]

@@Svanitterzon You could try casting some parts with the cut off. Edit Yes I know it is difficult to cast 7075...?

[@Salvolama]

Very, very great!! Thanks for this video.. You have a project for you machine cnc?

[@doctordapp]

Next step, making modified engine casings for a twin?

[@khashayarrowshanak5126]

Oh my lord 😥🤤😵... that looks pretty expensive

[@AsitShouldBe]

that's a properly used cnc mill!

[@xoeldopito1712]

top

[@kaba_me]

Cool... but I'd probably cast it.

[@adamabdullah8932]

Whats the brand name of the machine ?

[@Sibbe2560]

Wat een vakman...👍👍

[@cannondalehenk]

Stef, what does it take? Price? I am looking for a 5speed block.. Greetz Henk

[@hobbyrob313]

Man how do you get it done !? I am really amazed! (beautiful!) will this engine actually run? (I'm really curious!) Of course I believe so! BUT see first .... ;-) Healthy Greetings from Rotterdam! Rob

[@Svanitterzon]

Haha tnx rob, yes its supposed to work. Getting closer and closer to completion hope mabye next weekend to test it.

[@PowerRepublic]

sweet vid mate, what sort of NC are you using?

[@Svanitterzon]

Fusion 360

[@PowerRepublic]

@@Svanitterzon awesome job, love your creativity mate.

[@larryegilman1]

Artwork, with purpose!

[@fernandoalves2552]

Can you do it, with starter modification?

[@handjobsforthehomeless]

Holy shit! Nice video, why didn't you add a huge customized logo while you were at it? Maybe something fun on the clutch cover?

[@Svanitterzon]

Yeah i did. The engine is now almost finished. It had its first test drive and i put my family name on the clutch cover.

[@handjobsforthehomeless]

@@Svanitterzon Awesome man. If you don't mind me asking, how much does a piece of raw stock that size set you back?

[@Svanitterzon]

@@handjobsforthehomeless in total there is roughly 35kilo of raw alloy used for a 4 parts. Its roughly 400 euro.

[@handjobsforthehomeless]

@@Svanitterzon Thanks, thats just about the same price i pay here in the Netherlands. Keep up your great work man!

[@Svanitterzon]

@@handjobsforthehomeless haha ik heb het ook in Nederland gekocht.

[@barbeirorp]

Hello... Whats your rpm range of spindle

[@Svanitterzon]

6000 max

[@istvanlukacs9898]

Respekt!!!!!

[@TroubledTimes2024]

Just read where you made the mill, now even more impressive. Did you do all the CAD?

[@Svanitterzon]

Yes designed the mill my self, and i also make this 3d model for the engine.

[@asegify]

how many hours of machining in total?

[@annefrea88k]

How many hours did it take to mill the engine?

[@Svanitterzon]

Rougly 120 hours including trouble shooting and programming.

[@annefrea88k]

@@Svanitterzon jesus christ

[@annefrea88k]

@@Svanitterzon i have another question, i am looking into designing my own engine with a rotary intake valve and getting it milled at a machine shop. How many hours did the cutting only take for you? The hourly rate is around $60 for the cutting so i know how much it will cost me

[@hedning003]

where the heck did u get the files or g-codes for this?? or did u spend 2 weeks probing an old block out?? as a zundapp-owner and machinist i woud definitly like to know

[@Svanitterzon]

Haha, i used my mill as a cmm to measure each exact hole position. Rest of the shapes i draw my self. Then print the contour out on paper 1:1 scale and look if it matched. Just repeat this step like 15 times and you get pretty accurate shapes.

[@hedning003]

​@@Svanitterzon that sounds way to timeconsuming for me,but exelent work..i am impressed! those 280-blocks and especialy 284-blocks r getting hard to come by

[@dinkchow]

Did you ever finish the engine?

[@Svanitterzon]

Yesterday had the first test drive

[@loods1125]

Next a kreidler engine?

[@aaronfonseca6031]

What were the adaptive clearing feeds and speeds?

[@Svanitterzon]

Most of them 10mm endmill 3000mm/min 5400rpm 1.4mm woc and 12mm doc

[@aaronfonseca6031]

@@Svanitterzon ok nice, what is your spindle torque and total machine weight?

[@Svanitterzon]

@@aaronfonseca6031 Its a 3,7kw servo rated at 24N.m total machine weight is now i think around 1300 kg.

[@aaronfonseca6031]

@@Svanitterzon thank you very much, I’m getting a Syil X7-21 which is also epoxy granite :)

[@Svanitterzon]

@@aaronfonseca6031 oh thats a nice machine i have seen multiple videos about it online.

[@MSCNCArtshop]

I have an app developed for Eding CNC, I would want you to test it on your machine, would that be possible

[@Svanitterzon]

yeah i sended you a email about that a while ago, didnt you recived it?

[@MSCNCArtshop]

@@Svanitterzon I did not get your email address, email me [e-mail]

[@restorationandbuilds5899]

What did it cost to make this.

[@Svanitterzon]

A lot of time😅

[@djambush360]

Is there no ü on your keyboard? The name is "Zündapp" :-D

[@jeffjefferson2676]

So is this the 5 gear version?

[@Svanitterzon]

No its a 4 speed.

[@drp457]

This looks like a Hodaka case. Is it the same?

[@Svanitterzon]

Not familiar with that brand, its a copy of a Zundapp engine.

[@drp457]

search you tube for hodaka combat wombat.

[@Svanitterzon]

@@drp457 ah yes i see looks almost the same, but no thats not the one im building.

[@RMF_Retro_Moto_France]

Wooow!!!!!

[@Arjan-swets]

en dan een foutje maken.... :-)

[@Svanitterzon]

Zit een klein foutje in de positionering van de bout posities waar de cilinder mee vast zit. Heb dit kunnen oplossen door een nieuw overlappend gat te frezen en een helicoil in te draaien. Gelukkig heb ik dat kunnen oplossen.

[@Arjan-swets]

@@Svanitterzon :-) tja het is geen project... dat je zeg... ik doe hem nog wel een keer.... :-)

[@faisalsantos2574]

what grade of aluminum is used ?

[@Svanitterzon]

7075

[@gijsv8419]

Veel beter is er niet, of het wordt erg duur :-)

[@sjvche7675]

A Zundapp? OK

[@AWSXDER]

Какой дикий перерасход алюминия. Даже для мелкосерийного производства не годится. Надо было фрезеровать данную деталь из пенопласта, без отверстий. Затем, используя пенопластовую модель из алюминиевого сплава, отлить болванку. И уже ее фрезеровать обрабатывая только необходимые поверхности. Литье алюминия не сложный процесс, он доступен даже в домашних условиях. Он очень сильно снижает необходимое время работы станка ЧПУ, и позволяет очень сильно экономить материал.

[@cengizerencansz8229]

How did you get the cad file

[@Svanitterzon]

made the cad file my self

[@cengizerencansz8229]

@@Svanitterzon 3d scan or old school measuring ?

[@Svanitterzon]

@@cengizerencansz8229 oldschool measuring, i used my cnc mill as cmm to measure every hole in the casting the rest have been done with capilar.

[@cengizerencansz8229]

@@Svanitterzon I want to make cg 125cc motor block, where should i start ?

[@Svanitterzon]

@@cengizerencansz8229 i would first get all hole dimensions relative to each other of i where you. This way it doesnt mater how the engine gone look like the internals still will run smoothly as it should. Then draw the right shape around those holes. Make some test prints on paper and see if the contours fits. Or make 3d prints to see how it fits.

[@gijsv8419]

Een origineel blok is gegoten en dan bewerkt. Jij hebt alle maten exact overgenomen. Was niet makkelijker of interessanter geweest om je eigen carter te ontwerpen ? Bv wat strakker, of wat extra koelribben. Die mogelijkheid heb je nu met de moderne machines.

[@thefirstdutchguy]

WHY????

[@Svanitterzon]

Omdat het kan😉

[@jamesdenton3692]

MOTO Porn !! LOVE it .

[@seimela]

i am afraid of you boss

[@Svanitterzon]

Is that a good or bad thing😅

[@seimela]

@@Svanitterzon THIS is exceptional work bro , feel KZbin is not doing your content justice ,i have been following you from long ago ,your are doing awesome stuff .

[@gislemark79]

Pointless to make a copy and NOT improve it.

[@Svanitterzon]

Why? Once this is working i can add improvements then i know the model is right. And im able to machine these kind of parts

[@levashovsergey]

А нафига?