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Originally Posted by seafordguy
(Post 4780751)
It's deceptive but it hardly looks like the you'd have enough clearance under those VC's to clear the rockers. Obviously you do but it's just deceptive looking..... Coming together, I bet you're getting excited
https://cimg3.ibsrv.net/gimg/www.off...fc7d269e1f.jpg |
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No compression on one cylinder
Engine assembly is almost completed, pre-oiling with a drill showed a nice oil pressure, so I tried to turn over the engine with the starter. Went all well until I discovered that cylinder #1 has zero compression, all others are fine. Well, didnīt try with a tester, just with a finger but it is obvious that one cylinder has a problem.
Valves seem to open and close the whole way, but I donīt really know how to measure it. Took off the oil pan, all nice and clean, no debris or metal flake. Couldnīt see anything wrong at the cylinder walls or the piston from below. Any suggestions what I can do before taking the cylinder head off? Before I noticed that I had an issue I made a short video. Itīs not really focussed on the first cylinder, but something can be seen. |
Originally Posted by musthave1
(Post 4787122)
Engine assembly is almost completed, pre-oiling with a drill showed a nice oil pressure, so I tried to turn over the engine with the starter. Went all well until I discovered that cylinder #1 has zero compression, all others are fine. Well, didnīt try with a tester, just with a finger but it is obvious that one cylinder has a problem.
Valves seem to open and close the whole way, but I donīt really know how to measure it. Took off the oil pan, all nice and clean, no debris or metal flake. Couldnīt see anything wrong at the cylinder walls or the piston from below. Any suggestions what I can do before taking the cylinder head off? Before I noticed that I had an issue I made a short video. Itīs not really focussed on the first cylinder, but something can be seen. https://youtu.be/eZuQHT9hiLc |
Originally Posted by Rhythm and Blues
(Post 4787123)
Do you have lash at TDC compression stroke?
Frankly, I never fully understood how hydraulic lifters work, how they manage to adjust the lash autmatically. I set the valves to zero lash with the pushrod turning method, but I canīt say for sure if the lifters were filled with oil or not. Now they should be as after pre-oiling oil has traveled up all the way into the rockers. Shall I just loosen a little until I have some lash? I was concerned that without access to the pushrods I canīt fully control it. |
Lash is set with the up and down movement, not the turning method. Its turned a little back n forth to just keep it centered, but your going up and down until all that is out. Once all up and down is gone, this is zero lash point.
Since all have been done with the turning method, need to loosen all of them and get some oil back in them. |
Originally Posted by AllDodge
(Post 4787139)
Lash is set with the up and down movement, not the turning method. Its turned a little back n forth to just keep it centered, but your going up and down until all that is out. Once all up and down is gone, this is zero lash point.
Since all have been done with the turning method, need to loosen all of them and get some oil back in them. I used the wrong expression, I meant spin the pushrods between my fingers and tighten the rockers until the pushrod just canīt spin anymore to have zero lash. Then another half turn on the nut. Just by the book, but I might have made a mistake on the first cylinder. Anyway next time I go the boat I will try to loosen it and see if thereīs some compression coming and the issue can be solved that easy. |
Originally Posted by musthave1
(Post 4787142)
I used the wrong expression, I meant spin the pushrods between my fingers and tighten the rockers until the pushrod just canīt spin anymore to have zero lash. Then another half turn on the nut. Just by the book, but I might have made a mistake on the first cylinder.
Anyway next time I go the boat I will try to loosen it and see if thereīs some compression coming and the issue can be solved that easy. |
Another lockdown, another lost month, but yesterday finally I had my big day. 10 months passed since I pulled the seized engine and it was very exciting to start my first rebuilt engine.
Adjusted the valves again and got a quite high compression around 170 on all cylinders except #7 which is at 145 psi. Good enough for now. Checked all hoses, ignition and connections again, took a deep breath and hit the starter. Fired up almost immediately, idled without throttle, didnīt make any strange noises, no smoke, no vibration, no problems. That was easy. Even the timing was only slightly off so there was actually not much to do. Let it run for a while and that was it. Now I have two running engines. Thinking about opening the other one too, take the cylinder heads off to see if everything is ok. Or skip it and start something new? The outdrives need attention, Iīm sure they are in bad shape. https://cimg4.ibsrv.net/gimg/www.off...6b99480d9d.jpg completed engine before first start |
I left the country shortly after that last post above in May 2021 to escape yet another strict lockdown and what I thought would be a short trip to Europe. Instead it took me 6 months to be allowed back into Malaysia.
In the meantime somebody broke into my workshop, damaged the big roller shutter and stole some tools and parts, most notably my precious two-bank marine charger. Took me a couple of weeks to have everything replaced and repaired, had a surveillance camera system installed and so on. I was eager to fire up the engines, port engine hadnīt run in 10 months without any preparation whatsoever. But even with the weak battery it started immediately as did the starboard. Iīm always surprised how easy these engines start having carburator and no electronics. With that out of the way I took the outdrives off. They are not too bad but both transom assemblies are heavily corroded to the point that I canīt even disassemble them without destroying parts. Need to find replacements. Flying them in will cost a fortune but itīs probably the way I have to go. |
https://cimg0.ibsrv.net/gimg/www.off...7cc3247a03.jpg
Happy to have the big crane, makes taking the outdrives off easy |
https://cimg8.ibsrv.net/gimg/www.off...be548f8ef5.jpg
https://cimg7.ibsrv.net/gimg/www.off...117abfc4c6.jpg Had the stand custom made here. It is adjustable in width which I find convenient. |
https://cimg9.ibsrv.net/gimg/www.off...09cd975f58.jpg
Not a pretty sight. Note the broken oil hose. https://cimg2.ibsrv.net/gimg/www.off...ea5d8162b9.jpg Why is the bellow so dirty inside? https://cimg5.ibsrv.net/gimg/www.off...a65330750d.jpg Swivel pin worn out with a lot of slack |
https://cimg8.ibsrv.net/gimg/www.off...3c1959a9b1.jpg
Cylinders need refurbishing and so do the pumps. Got a new swivel shaft but couldnīt remove the old one yet. |
Pity about the break in, probably not much you can do about it having been overseas at the time. :mad:
As you dig deeper, there’s no shortage of ‘mini projects’ along the way. On the up side, good to know your engines fired right up. Take your time, it’ll be worth it in the end. 🙂 RR |
What's with the zinc on the skeg?? That will induce drag and probably do more harm than good.
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Canīt believe I didnīt post for 7 months. Time to revive my thread.
After taking the outdrives off I didnīt manage to take the transom assembly apart. After lots of WD40, hammering and swearing I called some locals who worked two entire days on it welding and torch-cutting, damaging only a few parts. But they made it. https://cimg0.ibsrv.net/gimg/www.off...42122d85c3.jpg https://cimg1.ibsrv.net/gimg/www.off...178559379e.jpg https://cimg4.ibsrv.net/gimg/www.off...3fd8416433.jpg https://cimg7.ibsrv.net/gimg/www.off...6295765c5d.jpg |
I also found a repair shop for the hydraulic cylinders and first thing they did was to disassamble them so I could see which parts to order. For the other parts I have my trusted chinese guy nearby who loves to stand on his even older turning machine and lathe me whatever I need in stainless steel.
https://cimg5.ibsrv.net/gimg/www.off...c366f71448.jpg the left swivel shaft is original, I still had it, the right is made here from SS304. Looking at the picture the thread looks different, have to check it out https://cimg2.ibsrv.net/gimg/www.off...0c5f48cb12.jpg |
and thereīs more, found a missing bearing, no wonder the starboard drive had so much play
https://cimg2.ibsrv.net/gimg/www.off...e8fe0aea91.jpg Gimbal roller bearing where it should be https://cimg1.ibsrv.net/gimg/www.off...8a60a2e1fb.jpg Missing starboard gimbal bearing Bell housing corroded beyond repair https://cimg2.ibsrv.net/gimg/www.off...94391799c6.jpg and all the small parts like this gimbal ring bushing or anti-galling washers https://cimg2.ibsrv.net/gimg/www.off...1a3aece325.jpg Finding spare parts for TRS is still possible but I had to gather the pieces from different sources including ebay. There is a lot of NOS, but some sellers just have, letīs say a single bushing, when you need four. Took months to get everything together, consolidate it and have it shipped to Malaysia. |
Keep up the good work! Looking good!
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Good to see you’re making progress, I’m sure it’s tough in Malaysia but slow progress is infinitely better than no progress. 🙂
Keep pushing slowly, it’ll be worth it in tne end. RR |
Flushed the drives with some cheap W90 oil, the original oil was deep black and smelly, but no water or metal pieces so I decided no to open them.
https://cimg8.ibsrv.net/gimg/www.off...028ad07725.jpg |
Fast forward a couple of months later, cylinders refurbished, stainless steel parts machined here, gimbal ring powder coated and new bearing installed, all small parts imported. Bought two bell housings from Tim, one was very good, the other one scrap, had to toss it. Found an aluminium repair shop which fixed one of my old housings and itīs now being powder coated.
Guess I have it all together, now I only have to assemble it. https://cimg2.ibsrv.net/gimg/www.off...7bd6bae785.jpg https://cimg4.ibsrv.net/gimg/www.off...e9e695755a.jpg https://cimg0.ibsrv.net/gimg/www.off...9d19c373cd.jpg https://cimg1.ibsrv.net/gimg/www.off...d54eb40afc.jpg |
Good machine shop is always great to have close by.
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Originally Posted by AllDodge
(Post 4845989)
Good machine shop is always great to have close by.
These two are originals, looking at the corrosion damage of the used one I have my doubts if they are 304 grade stainless steel. Then again, after 34 years in saltwater everything rusts. https://cimg1.ibsrv.net/gimg/www.off...d388822af0.jpg https://cimg9.ibsrv.net/gimg/www.off...77a193c950.jpg I posted this photo already but isnīt the shaft a piece of art? The $90 local reproduction on the right |
I would have given up long ago ... nice job
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Talking about spare parts, as mentioned before importing them is a lengthy and costly process so when I finally get them Iīm excited like a little boy on christmas. I spread everything on the floor and play with it :woohoo:
https://cimg6.ibsrv.net/gimg/www.off...907150307a.jpg https://cimg5.ibsrv.net/gimg/www.off...18869d4ae2.jpg |
Originally Posted by Griff
(Post 4821503)
What's with the zinc on the skeg?? That will induce drag and probably do more harm than good.
https://cimg8.ibsrv.net/gimg/www.off...44e1bc90f9.jpg Or maybe it was easier to install a new one than to replace this https://cimg8.ibsrv.net/gimg/www.off...3c471f6262.jpg |
Originally Posted by musthave1
(Post 4846019)
Talking about spare parts, as mentioned before importing them is a lengthy and costly process so when I finally get them Iīm excited like a little boy on christmas. I spread everything on the floor and play with it :woohoo:
https://cimg6.ibsrv.net/gimg/www.off...907150307a.jpg https://cimg5.ibsrv.net/gimg/www.off...18869d4ae2.jpg |
Originally Posted by offshoredrillin
(Post 4846252)
are you ordering double of everything to have spares? that is if the budget allows it.
For now I do stock spare filters, impellers, belts and gaskets. Of course Iīm way over my budget already, typical newbie I underestimated how much money I would spend, especially on all the little things like stainless steel nuts and bolts and screws, line holders, quality tinned cables, connectors, AN fuel hoses, gaskets, the list seems to be endless. Sometimes I have an order for a thousand bucks and it fits into a shoe box. And Iīm still buying tools. But I donīt want to disencourage anybody, I still believe itīs worth the effort. |
some new parts
https://cimg0.ibsrv.net/gimg/www.off...7db3444fc4.jpg https://cimg8.ibsrv.net/gimg/www.off...e421dd0ae7.jpg Port engine gets new parts too, e.g. starter, alternator and ignition cables. https://cimg9.ibsrv.net/gimg/www.off...dcbe6ed5eb.jpg https://cimg1.ibsrv.net/gimg/www.off...4c69932594.jpg https://cimg2.ibsrv.net/gimg/www.off...f240097f82.jpg https://cimg3.ibsrv.net/gimg/www.off...93644ca33c.jpg The intake side of the blower is normally used in trucks and itīs nearly indestructable. I tortured it with a heat gun, a lighter and fuel and it took it all. Perfect to bury it deep in the bilge. |
More to adress
https://cimg5.ibsrv.net/gimg/www.off...32caa5430f.jpg Before https://cimg0.ibsrv.net/gimg/www.off...1130602e21.jpg And after: New fuel pump/filter module ready to install https://cimg8.ibsrv.net/gimg/www.off...3fd37ba3de.jpg Upgrading fuel hoses https://cimg9.ibsrv.net/gimg/www.off...5c99f4494e.jpg Trying to figure out what I need to order https://cimg6.ibsrv.net/gimg/www.off...31869f5c06.jpg Before https://cimg1.ibsrv.net/gimg/www.off...9595dc3d95.jpg And after: Powder coated and new parts, still doesnīt look as good as a modern stainless steel strainer. I might buy a new pair later as the starboard side of this type was stolen anyway. https://cimg7.ibsrv.net/gimg/www.off...4c94fe33d7.jpg One of the old bilge pumps was still working before removing |
You’re divin deep! Nice work. The motors look really nice. Looking forward to seeing it all back together and some running shots!
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Awesome project! You put in some serious hours on this thing!
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