looks great Charlie  

should be proud of her

Yup!

It's great to see you're nearly good to go with redframe, Chaz.
 

Wow big job,  thanks for sharing it.  Even just posting this is a big task.

Sweet looking ride you have there, Charlie!

Are you going to bring it over on saturday for the rego check?

Looks fantastic Charlie!  I wish now that I had also painted my frame red as i had originally intended - sharp as hell!  I hope you get great enjoyment from from your now almost complete project.

cheers Woodie and all


just an update
a parcel arrived late today with some bit for a future project on Gerty , and a heat shield for Fred

all the usual bumps scratches and rust hiding in there

a quick Charlie treatment , and we have some colour deployed and drying















about an hour and a bit turnaround ....giggles

fred has an official- Charlie  model designation

well ....hard to give it a bmw colour code or anything ...eh ?

Charlie, are you going to leave Gerty and Fred alone, together in the garage over night? My concern is allowing a male and a female together...will we have little Ks arriving?

well finished the heat shield, turned out ok ...I guess

installed fibre washers between the shield and the mounts to quieten down the metal to metal contact , and more fibre washers between the bolts and shield






unfortunately that made the nice dome headed screws that I had cut down especially for the job ...too short ,,,bugga !!!!
oh well had some standard screws in the kit so installed those for the moment and until I can get some others








looks ok for a rattle can job ...eh?

dng shame to hide all that lovely stainless on the silencer ....sighs ....

I think Fred will get lonely! None of us will dare park too close for the shame of the comparison.

Fantastic job, Charlie. Looking forward to seeing it in the flesh sometime.

Bill

about to be off for the club rego day over in Inverell ,,,very excited
hopefully will have a plate on the back come Monday morning when the RMS opens

Congratulations Charlie, Hope all goes well at the rego. check day. AND may Gerty and Fred create many more K's.
Cheers
Tom

hmm did some investigation

looks like the big end and crank journals are ...well not toast , but no white metal left , back to base metal

signs that the oil pump issues that I fixed have taken its toll and likely running low pressure , over a period of time

so im looking for another motor to rebuild , with a good bottom end to start with ... which I might have sorted , time will tell ... but a good deal more work to put into the project .


its all back together, but not going to think this engine has a lot of life in it ....

bugga

Fark.....

ooshit

No doubt the " Charlie treatment" will be used to rebuild another engine and then enjoy the result. Keep at it mate.

Man that sucks Charlie.  Did you get it registered?  Can you ride it while you work up a new replacement engine?  I'd be happy to help you out with a spare that I have but postage to Oz might be a bit of an issue.    If good wishes are worth anything then you have them coming your way from all around the world.

Sorry to hear Charlie, I'll keep my ear to the ground.
Regards Martin.

pics to come as I get into the engine , big knock sound emanating from the , what appears to be crank end ...after the toy run ride last Saturday

have some old spares including a reasonable crankshaft , and some main journal slippers that should be ok , many thanks to Rick g
every big end ive seen that I have  (except for gerty ) has some bad wear marks on the slippers and or back to base metal instead of white metal - the hard stuff .

likely to order new slippers - shells for conrods .

have just cleaned up pistons and conrods out of an '90 engine , which look ok

and if going in that deep, ill likely adjust the weights of pistons and rods to match each other

Bummer of a problem, but very glad you have a way out sorta sorted. Let me know if you have any particular spare parts needs, Chaz. I might have it in my stash and am attempting a comeback trip in March or April when I can see 20-20 more clearly .

fingers crossed for you Dazza

think ive found the issue


looks like the sprag clutch assembly , auxiliary shaft  has moved some what ....and just binding on no 4 conrod when it passes

I remember having to do up the alternator drive thingy , but from memory its a splined fitting into the shaft , did it get out of alignment and give me a false impression that it was tight ..

ill have to lookup the bolt size so I make sure its the right thing , and likely have to fiddle about with the spline - couplings somewhat to draw the gear away from the conrod - further out in line with the cut gear ....with fingers crossed I recon , this may not be an easy thing without complete disassembly of that bloomin bell housing


here's what i'm seeing at the moment

any ideas ????

sorted !!!!  yipeee   !!

found the correct keyway - spline mesh , and the bolt pulled the gear back about 4-5 mm

and now is quite tight ..





might replace that crank while i'm in there   and some new big end slippers - shells

no Doubt you just caught that in the nick of time!

Sheesh! A combination of good luck and good spannering!

might put this '90 crank in there , now its apart ...erm somewhat , just the timing cover to remove and refit the chain after

will be better than the current offering , I guess stressed by an earlier event with the oil pump

current state of the 83 crank before intervention , typical





shells






new to me 90 crank, cleaned up a bit ....lol



new big end slippers - shells ordered   , will make do with the best that I have for the journals

think ive done all I can till parts turn up

just waiting

Christmas present? Will Santa bring the parts on the sleigh?

lol ...likely Stan ...aus post could well be running late ?

still waiting
but decided to fit up the new to me crank , freshly lynished , was hoping to do this all at the one time with the conrod slippers as well , but ,

out of 3 or 4 sets of main journal slippers I had to hand, found the best that I could and fitted it up

with just a few adjustments required on a couple of pairs was able to get the clearances back to just under 1 thou all across





getting there , slowly

Slow & steady, we often are reminded, wins the race.

upon reassembly of the crank and running gear , there seems to be a fairly loud click emanating from the bell housing , not evident before

the click appears to be timed at about twice the crank revs and emanating high in the bell housing , so by reasoning could well be one of the bolts holding the sprag clutch together .

I would think that the con rod hitting the aux shaft driven gear could definitely send some strong vibrations along that assembly

so ill back off trying to get it fixed and running till after this weekend,  and explore that next week.

well in the bowels elbows deep  to inspect the damage .
seems that the bearing on the sprag clutch shaft has been destroyed- spun out of location  , taking the face of the housing with it, to a degree

I have another sprag assembly for comparison - spare - swap if need be

options ....complete new block  and transfer everything over ?  or perhaps just a new bearing , as the depth of the housing seems ok  + a bit of Loctite glue in place ? with the spares that I have .

If the gap isn't too big, I would Loctite it.
The safe side is another housing.

I'd go for the new block. I have a pathological dislike of trying to 'reuse-fix' any bearing surfaces that run directly in the ally because once it's worn, IMNSHO, the only way out is to fit something like a bronze bearing. That's just my 2C.

I have a few here he can take his pick.

RicK G wrote:I have a few here he can take his pick.

Toystore

What's that Skippy?

yeah, I think ill do a rebuild - swap over into another block

so it all starts again ....bugga !!!!


some pics  before









during cleaning












shoot lots of work to do still to get this looking ok


but the housing for the sprag looks to be intact

I know the feeling Charlie. A not-quite-as-bad story but... a few years ago I had a set of Moto Guzzi engine cases vapour-blasted, then rebuilt the engine and very carefully put it into storage. There's a leak in my garage roof when the wind and rain are in the 'right' direction (shitty builders - had them back twice and of course, twice they turned up on a sunny day. 'No, nothing wrong there'). Only I didn't put the engine into storage carefully enough. The sheet covering the gearbox got wet when I wasn't looking and left a dirty great streak of corrosion all down one side. I haven't had the heart to strip it and go through all that again yet.

ouch Dai !!!  a real pain indeed


I guess its been a long day , with riding adventures along sparsely populated bush tracks , only to find the road closed off before destination achieved...bloomin fire risks ... but a good day out with riding friends

I guess this will do, till tomorrows challenge  , exposed areas clear coated for protection

sump work version 2

cleaned up by sandblasting the black paint off



and what im hoping to achieve all along  , a clean aluminium satin look

Suddenly... you end up with a piece of art

Nice job Charlie

almost down to the last remnants of the 83 motor to come part

moving all the parts to the 90 motor that I was lucky enough to acquire from Rickg , as its the best option I have at the moment

there are some differences in the pistons rings etc  over the production years on this 90 motor

but have balanced up the weights of rods and pistons to each other  , to the best of my ability  with tools to hand and hope that it may make a smoother running engine

ring gaps were similar to gertys (at 200,000 k  round about)  at 20 odd thou gap, so that's not too bad  , the 83 engine was 30 thou gap , so some advantage to be realized ,. I hope .

assembly soon to occur as new parts arrive for the output shaft (small end bearing and running bush ) as it seems that with wear in that bush and bearing seems quite consistent with the acquired mileage across a few I have seen .

block and pistons ready to go in ,  as soon as I can get the right ring compressor
have had issues fitting the piston rings back into the block with an oversized ring compressor that is hard to control as compression is approached , ( the pinned second compression ring , fighting the snap action of the compressor that I had as it approached full tighten , snapping two rings so far ...bugga )


big end slippers have been replaced for new (with some white metal actually on them , instead of base metal appearance )  and journal slipper selected from the best I have across several motor parts here , and reusing the 90 crank as it appears to have the best surface , close to original as I can see .
also have resolved what appears to be a sticky lifter , on dismantling ,  found a score vertically in the bore of output 2 , restricting rotation etc , now linished and back to smooth operation as far as I can see.

but hopeful to get a right sized compressor tool soon and  finish that part .and let me finish off buttoning up the motor

head gasket and bearing parts on the way...slowly it seems ...

some pics 



 

charlie99 wrote:block and pistons ready to go in ,  as soon as I can get the right ring compressor
have had issues fitting the piston rings back into the block with an oversized ring compressor that is hard to control as compression is approached , ( the pinned second compression ring , fighting the snap action of the compressor that I had as it approached full tighten , snapping two rings so far ...bugga )

What's wrong with the old two screwdrivers approach? 

I've used this ring compressor successfully in a variety of bore sizes for many years, though in the 'olden days' I wasn't too far away from a coupla thin strips of plastic or ice cream sticks set opposite one another to ease the piston & rings into the bore.