Author Topic: Racer Resurrection  (Read 65392 times)

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Offline OldSwartout

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Re: Racer Resurrection
« Reply #200 on: August 14, 2018, 07:31:24 PM »
It only needs to clear the driven gear on the end of the alternator.  Just clip it off with a cutoff wheel in a die grinder and get it relatively flush. There is a reasonable amount of clearance behind the gear and you can easily check it visually. It's not necessary to go to all the trouble to set up a mill cutter.
Karl Swartout
Mooresville, IN
BS175 Roadracer
BS350 GTR

Offline al_pritchard

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Re: Racer Resurrection
« Reply #201 on: September 13, 2018, 04:13:07 PM »
Figured a quick update was in order. Not a lot of progress on the engine, but all the parts are in. And that pesky shaft/nub is no longer in the way.

Most of last weekend was spent at NJMP watching the super bikes play in the rain. Interestingly 3 of the last 4 MotoAmerica races in NJ were in the wet. The USCRA guys were also in attendance, and like last year It was fun watching them go round.

I did manage to find a little time between rain drops on Friday to put the final coat of clear on. Ended up going with white. I think it looks rather nice with the big Bridgestone markings.

The under lying color is your standard Rustoleum. With a top coat of USC 2K high gloss clear. Very impressed with how this went on. It’s a 2 part clear, you “pop” a button on the bottom of the can shake for 2 min, and spray. And it’s full proof - I hope.



Al Pritchard
Highlands, NJ

BS175 Racer

Offline rwgibbon

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Re: Racer Resurrection
« Reply #202 on: September 14, 2018, 07:13:17 AM »
Very nice!

Offline al_pritchard

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Re: Racer Resurrection
« Reply #203 on: September 27, 2018, 02:01:27 PM »
Thought I was making such good progress over the last two weeks. The “nub” has been removed, everything is scrubbed clean and oiled up. All new seals, and even new head studs. Assembly was moving smoothly, then…

 :'(

I striped out the cylinder head stud hole in the block. I’m going to try to open it up, and install a helicoil without stripping the engine down again. Otherwise it all comes apart, and gets resembled again.






Al Pritchard
Highlands, NJ

BS175 Racer

Offline OldSwartout

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Re: Racer Resurrection
« Reply #204 on: September 27, 2018, 07:08:30 PM »
Damn!  Yes, helicoils work for that, and it really shouldn't be hard to keep the chips out of the bottom end. I've done one or two over the years.
Karl Swartout
Mooresville, IN
BS175 Roadracer
BS350 GTR

Offline al_pritchard

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Re: Racer Resurrection
« Reply #205 on: October 11, 2018, 01:25:27 PM »
Whats that saying, use the right tool for the job?

After 7 un-successful attempts with the original “official” Helicoil kit. I ordered an e-z coil kit. First attempt, success! The e-z tool keeps the coil comprised as it threads into the hole. The helicoil tool does not have a way to keep compression on the coil. So it expands, and attempts to cross thread the hole.

So product recommendation. If you want to use a coil based thread prepare method. Get eh E-Z Coil kit.

To do it all over again, I would probably get a Time-Sert kit. I like the idea of having the top hat that time-sert provides. In the case of the coil, you need to install it slightly below the top of the hole. Not a bit deal in most cases, but the head stud is slightly narrower than the hole needed to install the coil. So the stud is going to be slightly shorter by a thread or two. Shouldn’t be an issue.

Now I can get back to building this engine.

Massacred Helicoils


Get this tool!


It makes this easy


And fixed
Al Pritchard
Highlands, NJ

BS175 Racer

Offline al_pritchard

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Re: Racer Resurrection
« Reply #206 on: October 15, 2018, 01:16:36 PM »
Managed to steal a couple hours over the weekend - double duty watching WSBK, and building an engine.

One of the nice surprises that came with the spares package is a packet of new SR clutch plates - Thanks Richard! It’s good to, because two of the plates that were in the bike were broken.

Assembly is going smooth, with everything seeming to fit where it should. Fingers crossed…






Al Pritchard
Highlands, NJ

BS175 Racer

Offline al_pritchard

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Re: Racer Resurrection
« Reply #207 on: November 06, 2018, 06:54:56 PM »
I guess third times the charm.  ;D

It seems that the oil seal on the transmission output shaft needs to be put in place, before the case haves are joined. Lesson learned. So, now that we have everything back to gather again, I have a question.

I'm using the aluminum shims from Cometic, between the case and the cylinders. Should I also be putting a little Yamabond on both sides of the base shim? Or will the aluminum of the shim be soft enough?

Oil Seal
Al Pritchard
Highlands, NJ

BS175 Racer

Offline OldSwartout

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Re: Racer Resurrection
« Reply #208 on: November 07, 2018, 08:17:44 AM »
IMO, go with Yamabond or something similar, won't hurt and may prevent an air leak that could cost you a piston and cylinder. If a head gasket leaks, you'll see it and it won't destroy your engine.  A cylinder base leak might.
Karl Swartout
Mooresville, IN
BS175 Roadracer
BS350 GTR

Offline bsracer

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Re: Racer Resurrection
« Reply #209 on: November 10, 2018, 03:07:43 PM »

Offline OldSwartout

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Re: Racer Resurrection
« Reply #210 on: November 10, 2018, 07:34:05 PM »
This is what I
use on the heads and on the aluminum base shims.

paul

https://www.permatex.com/products/gasketing/gasket-sealants/permatex-copper-spray-a-gasket-hi-temp-sealant/
Agreed - that's what I used on head gaskets. I didn't think about it for the aluminum spacers, but makes sense.
Karl Swartout
Mooresville, IN
BS175 Roadracer
BS350 GTR

Offline al_pritchard

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Re: Racer Resurrection
« Reply #211 on: November 13, 2018, 12:10:11 PM »
I used a copper spray on the head gasket when I restored the Jeep. It worked - and still is working - very well. Didn't even think to use it for the base shim. Might transition to it when I pull the heads off next time. The Yamabond is a little messy, and not very good at transferring heat.

I did manage to get the engine all buttoned up this weekend. Fingers crossed I did it right. Also set the static timing to 24° BTDC (2.356mm or 0.092in BTDC) The photo below shows the magnet rotated to about TDC. The Dyna fired about when the blue line gets to the raised edge of the pickup. I may go in, sand off the blue lines, and reposition them to allow me to mark the timing on the pickup. For now it's marked on the side of the generator case, and the engine case - blue marks.

Also started practicing my safety wiring skills.







Al Pritchard
Highlands, NJ

BS175 Racer

Offline craig641

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Re: Racer Resurrection
« Reply #212 on: November 14, 2018, 10:43:18 AM »
Double check your safety wiring on your exhaust studs.  The one on the right is wired so it's loosening the nut, not tightening it.

 


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