Well, it's not a blaster but it IS a full rebuild....
For those following the "new tools" pics/vids thread this is a repeat, but for those who haven't been here you go!
I went yesterday and traded a Lincoln Promig 135 100V mig welder and a 150cf Argon/CO2 bottle that was half full for a broken engine driven welder. The welder was listed on CL for $500 or trade for 3 point attachments. I made the pitch (mainly for giggles) expecting him not to even respond and much to my surprise, he was interested.
The welder he had is a 16 hp Hobart AC/DC CC/CV 225 amp welder. The guy owns a mobile home relocating company and some of his employees were moving from one site to another and one of them forgot to strap down the welder. It slid off the flat bed at about 10mph and hit on the back left corner. The main damage was taken by the shroud but the engine took a good whack as well. It broke the left side spark plug and oil filter adapter and bent the cooling air shroud.
The main damage, however, was from sitting since the incident..... 3 valves were stuck (both exhaust and one intake) and the whole engine unit is rusty here and there. The carburetor is dried out, the fuel left in the tank is funky, and the oil has sort of congealed....
I started yesterday by pulling off the engine shrouds and the oil filter adapter. I then tried to turn the engine over by hand and it would turn a few degrees and stop. I removed both spark plugs and poured marvel mystery oil down in each side and then pull the intake manifold and exhaust off. Examination revealed the stuck valves.
I poured marvel mystery oil down in each of the 4 ports and began to pull both heads. I ran into the first real trouble on the left side head when 3 of the head bolts were unusually tight (the rest unscrewed by hand once the torque was undone). Two of them came out with liberal amounts of penetrating fluid and bunches of "back and forth" threading. One wrung off in the block nearly smooth with the mating surface. I tried the usual, visegrips, heat, and more penetrating fluid and none of that helped. There just wasn't enough left hanging out to grab onto....
I decided to try the easy out (despite the knowledge of how much it took to wring it off....) so I got out the drill and proceeded to ruin the cutting surface on no less than 3 drill bits, two of them titanium nitride coated. I looked at the other bolts and wiped them down to reveal the marks on the surface..... grade 8!
I went and got the oxy-fuel torch (MORE HEAT!) and STILL didn't touch it. I decided more "help" was needed and consulted with a few folks on the BF chat last night.
I decided this morning to use the tools available to do what I could.... I put in a 1/4" pear shaped double cut tungsten carbide cutter in the air pencil grinder and went to town. After about three hours of lubricant spraying and burr grinding, I finally busted all the way through the bolt. I then over-drilled it to 21/64" and tapped the hole for a heli-coil installation
I also worked the crank back and forth until I freed up the stuck valves/guides (no damage, just cruddy stuck!) while the heads were off. I cleaned all of the piston crowns, valve faces, and intake and exhaust ports out while I was at it.
Now the engine turns over freely!
Anyway, onto the pictures:
All of the penetrating fluid I used on that headbolt pooled onto the floor below the engine and the general shape of the shop:
The left side cylinder, the bolt has already been ground out and the threads repaired. They're the top right corner ones.
The right side cylinder precleaning:
For those following the "new tools" pics/vids thread this is a repeat, but for those who haven't been here you go!
I went yesterday and traded a Lincoln Promig 135 100V mig welder and a 150cf Argon/CO2 bottle that was half full for a broken engine driven welder. The welder was listed on CL for $500 or trade for 3 point attachments. I made the pitch (mainly for giggles) expecting him not to even respond and much to my surprise, he was interested.
The welder he had is a 16 hp Hobart AC/DC CC/CV 225 amp welder. The guy owns a mobile home relocating company and some of his employees were moving from one site to another and one of them forgot to strap down the welder. It slid off the flat bed at about 10mph and hit on the back left corner. The main damage was taken by the shroud but the engine took a good whack as well. It broke the left side spark plug and oil filter adapter and bent the cooling air shroud.
The main damage, however, was from sitting since the incident..... 3 valves were stuck (both exhaust and one intake) and the whole engine unit is rusty here and there. The carburetor is dried out, the fuel left in the tank is funky, and the oil has sort of congealed....
I started yesterday by pulling off the engine shrouds and the oil filter adapter. I then tried to turn the engine over by hand and it would turn a few degrees and stop. I removed both spark plugs and poured marvel mystery oil down in each side and then pull the intake manifold and exhaust off. Examination revealed the stuck valves.
I poured marvel mystery oil down in each of the 4 ports and began to pull both heads. I ran into the first real trouble on the left side head when 3 of the head bolts were unusually tight (the rest unscrewed by hand once the torque was undone). Two of them came out with liberal amounts of penetrating fluid and bunches of "back and forth" threading. One wrung off in the block nearly smooth with the mating surface. I tried the usual, visegrips, heat, and more penetrating fluid and none of that helped. There just wasn't enough left hanging out to grab onto....
I decided to try the easy out (despite the knowledge of how much it took to wring it off....) so I got out the drill and proceeded to ruin the cutting surface on no less than 3 drill bits, two of them titanium nitride coated. I looked at the other bolts and wiped them down to reveal the marks on the surface..... grade 8!
I went and got the oxy-fuel torch (MORE HEAT!) and STILL didn't touch it. I decided more "help" was needed and consulted with a few folks on the BF chat last night.
I decided this morning to use the tools available to do what I could.... I put in a 1/4" pear shaped double cut tungsten carbide cutter in the air pencil grinder and went to town. After about three hours of lubricant spraying and burr grinding, I finally busted all the way through the bolt. I then over-drilled it to 21/64" and tapped the hole for a heli-coil installation
I also worked the crank back and forth until I freed up the stuck valves/guides (no damage, just cruddy stuck!) while the heads were off. I cleaned all of the piston crowns, valve faces, and intake and exhaust ports out while I was at it.
Now the engine turns over freely!
Anyway, onto the pictures:
All of the penetrating fluid I used on that headbolt pooled onto the floor below the engine and the general shape of the shop:
The left side cylinder, the bolt has already been ground out and the threads repaired. They're the top right corner ones.
The right side cylinder precleaning:
