Cheap Junk 1971 Build

[Piledriver]

Use the handle or a brass drift for contact...

[oprn]

Well the hammer trick didn't do anything. I don't want to hit it any harder so some material needs to come off something. My tool and die maker friend doesn't like the sandpaper idea due to grit being left in the soft bearing material. Maybe a file is the answer.

[Tony Z]

I use 600 or 800 grit waterpaper to sand the bearings. Havent had a problem yet.
I actually tried the hammer trick yesterday too and it also didnt give me the results I hoped for, so out came the sandpaper/waterpaper

[Piledriver]

Silicon carbide paper should probably be avoided due to the way it fragments, diamond coated mylar film is probably ideal..
A sheet can go for years, depending on use.

A fine diamond hone (diamonds in nickel, either over plastic or SS) is also an option, commonly used for sharpening knives etc.
I actually got a custom Webcam that was under std spec once, its like they forgot to finish the thrust.
That took a lathe to fix.

[oprn]

This is a new Webcam and yes I am wondering if it is under spec. I will compare it with the stock cam and chuck it up on my lathe if need be.

[Piledriver]

Go for the best possible finish. It hit mine with film out to 12K grit...003-.004" clearance.

[oprn]

Cam was fine, trimmed the thrust surface to get .003" clearance. It seems the cam bearing is just aluminum all the way through. I was expecting a soft babbit wearing surface that I would have destroyed doing this. Not so.

[oprn]

My cheap junk build hit a snag. I checked the deck clearance on one of the cylinders and it was good so went ahead and put the heads on and torqued them. Next I put the rocker arms on so I could start working on the rocker geometry. Oops! Engine doesn't make a full turn now. Deck clearance issues still or are there valves hitting the pistons?

Out of time, too many spring, summer, yard, work things going on now. Old 1600 DP went back in for the summer rather than rush the good engine.

[Piledriver]

Pull thr rockers and you'll know quickly.

[oprn]

So - summer is gone with all it's hustle and bustle, fall has past, garden cleaned up and winter is upon us, firewood hauled home, mostly cut up and needs splitting. Won't take long. Time to get that engine finished and into the buggy? Guess again. The well just caved in and we have no water in the house. Looking at two weeks minimum to pack water by hand, get a driller, trench in a new water line and 15 grand or so spent!

Arggg!! Why does life conspire to aggravate me so?!

On the plus side we did get to enjoy the Buggy with the tired old type 1 in it. We even made one 21 hour trip that only used 3 quarts of oil. Mosquito control for the locals as we passed through!

[Gnasha]

Im up to page three, Ive had to stop, just to be one of those guys who have given you positive comments, for what is an addictive compelling read.

Its like a best selling novel. back to page three.

thanks again

John (UK based)
PS love this..... "Mosquito control for the locals as we passed through! "

[Gnasha]

Tony Z, glad to see someone watching.

There is always somebody watching

Indeed

+1

[oprn]

Pull thr rockers and you'll know quickly.

Right you are! It's valve interference beyond a doubt, I will recheck the deck height but it looks like I need to cut some clearance in the pistons. Is this common on type 4 engines with flat top pistons? The previous build on this engine with stock cam did not have this problem.

Unless the cam is way off time - is that even possible?

[Piledriver]

A stock cam has ~no overlap.

Unless you actually measure everything you are only guessing and hoping for a good outcome, much like buying a lottery ticket with slightly better odds.

[oprn]

It looks like my best option is to rig up an old valve in and old head with a cutter on it to make some clearance. There are no competent engine machinists within many hours of here. With the exception of a buddy who is a retired tool and die maker that would no doubt look over my shoulder and give advice if asked I'm sure.

I really don't want to use cylinder spacers and go big on deck height to do it.