Proton KR3 - Built by Team Roberts from New Zealand to Goodwood

Apart again!

I could not send it to the UK with the leaking crankcases.. would not be possible for anyone else to run it..had to have a better solution.

Water in cylinder two is dodgy as it can fill the combustion chamber.. turn it over and not compress and bend the connecting rod..now a good look with no parts!

Also the O rings on the base gasket area were broken and not sealing due to age.. (Nice detail in that area btw.. o ring on the crankcase.. then shims to set the deck height then o rings on the cylinder.. nice..)

The main issue is around the water galleries feeding up into and around the exhaust port.. all corroded and no groove left to support the o rings.

A bit of noodling with my fitter and turner mate Tjebbe!...we have done many crazy project together all over the world!

A very good CNC machinist who I worked with on the BSL500 project was prepared to have a go... machine the cases.. and make new inserts to hold the O Rings. Critical to get the depth right..and voila!

Did this on all three cylinder bases on the crankcase.

While we were at it had them machine up an o ring mold.. so we could make new O rings for the base gasket..

Then mold the O Rings

Back together...again...

Noooo......

More water in Cylinder 2!

Had the call from Chris saying we were off to Goodwood!.. Yay!... Pulled the bike out of the hallway in the house (as it is a piece of art!).. thought .. lets run it and give it a final once over...

Noooo..... leaking badly into Cylinder #2....

Now I am starting to lose my sense of humour now! The poor lads!

The clock is ticking.. to Goodwood Festival of Speed

Bugger!.....well noting for it but to strip it... again...

The cases must be porous in the crank chamber...(it had had something go through it )..

We are getting good at this now... about an hour and half to get it to bare cases...

I hadn't wanted to touch the previous bogging... as I thought it was sealed and didn't want to disturb.. silly boy.... ground it all out and discovered a new sealant..

The outdoor grinding setup!

Once filled we need to make a mandrel to shape the bottom of the crankcase.. too hard to machine... so Veg 3D printed a "tool".. we used a steel blade attached to the mandrel... worked a treat..

New sealant.. we called it Shrek Goop..

We are getting good at this now!

Now... pressure test.. Veggie....she holds pressure!

Back together she goes.. again.... we are getting good.. qualifying starts in an hour!!.. Sam is getting quick at this .. the new apprentice! Ashley is the sanity around the shop also!

Back on the dyno!

Well now we can run it again.. this time quite hard to see if it leaks...

The dyno is so good to start this now.. and run it safely..

It has no chokes so a little "Easy Start".. and starts easily... ohh.. and after a lot of research we found a "Waterless Coolant" Evans Waterless Coolant.. especially for magnesium crankcases for aircraft.. do not use any water!

Starts nicely.. runs well....

Left it for a day and it dripped a little coolant.. not into cylinder 2!.. but out through the crankcase wall.....ff thing.. only small but a bit disappointing... not big enough to worry about.. reminded me of a typical Suzuki RG500!

A few more runs... a few more sanity checks.. gearbox and everything ready to go so I can take it out of the crate at Goodwood..plug in the battery and off she goes!

Ship it!

Shipping....this thing does not want to leave!

So we built a crate Thanks TSS Motorcycles in Lower Hutt! Especially Andrew and Jay Lawrence! Great supporters of our sport and in particular this project!

Even 3D printed a stencil for the crate.. very professional! Hope Chris likes it!

Out of here.....or so I thought!

Booked on a flight to the UK.....

Security!!

I am in Auckland on business and for my Aunties 101st Birthday celebration!.. Go girl!

Get a call... we have an issue with the motorcycle in the crate.. we have off loaded due to serious security concern we have spotted a liquid material and a battery and wires.. it is in a compound awaiting the bomb inspection...!! Ohh for ff sake! This thing does not want to leave!

Down to the airport.. stop at hardware store to buy snips.. screw driver etc.. to remove thr Evans Waterless Coolant!.. the spare battery.. and the wiring!!

They were seriously not happy!... cooled them down and off it went... finally!! Next stop UK!

UK - Finally

Flew to the UK.. then popped down to Ramsgate to meet Chris Wilson... I had not been in the UK for 22 years! Wow.. what a zoo....another story.

Chris's hospitality is second to none.. Andrea his wife and James their son are absolute treasures.. so pleased to be in there neck of the woods!

Popped in to Chris' work we he reconditions aero turbines.. very cool!

Goodwood here I come..

They are ready for us!!

I think Chris is pretty happy!.. my partner in crime in the background Tom Dermody another collector of lovely racing motorcycles.. from Brisbane.

So pleased I did all the testing at home!

The Boss turns up!!

Well pretty pleased to meet up with Kenny again...

I worked for Kenny for about 12 years back in the day..

I asked him what bike he would like to ride... "I am riding my bike!".. pointing at the KR3 (Kenny Roberts 3).. we had exchanged a few emails and there were some maybe I am coming maybe I am not... and what to ride etc etc...

Pretty stoked that he was going to ride the bike that we had bought from New Zealand, had worked on for nearly three years... and Chris had had the faith that the Kiwis would make this all happen...

By this stage I am upside down with time and jetlag.. feeling rubbish with a chest infection.. but so pleased to be here with the lads.

Of course my old mate Wayne Rainey is riding also at Goodwood which is pretty special but I am focussed on my project Kr riding the KR... how cool is that!

What a team!

Goodwood Festival of Speed

Lots of other older Links to the side! ->>

Such a privilege to be invited to attend. So many thanks to Chris and arranging for the Duke of Richmond to invite me and accommodate me for the event. What an honour for a kiwi lad.

I originally went to the US from New Zealand as I wanted to go to Daytona to see my hero ride at Daytona.. None other than Kenny Roberts.. who would have thought that he would be riding the bike I have spent three years working on at the largest classic motorsport event in the world..

A few pics to enjoy..

The A Team