let the games begin - R69s engine rebuild

User avatar
malmac
Posts: 501
Joined: Sun Jun 29, 2014 2:10 am
Location: Toowoomba, Australia.

Re: let the games begin - R69s engine rebuild

Post by malmac »

Daves79x wrote:
Wed Feb 17, 2021 7:39 am
The real fun is yet to come. Do yourself a favor and heat the case in the oven to at least 300 degrees F. Obviously freeze the crank overnight. The crank will fall in. And still retain enough heat so the rear bearing race does not stick when drawing the assembly forward into the front carrier.

Dave
Dave

Thank you for the heads up on the heat. The last time I only heated to 200F and it cooled down so quick it was a bit of a struggle. I will certainly take your advice re the 300F.

Re the slingers rubbing. I am sure you are right re the specified spacers working most of the time.
The last engine I did, I fitted a reproduction front bearing carrier.
To get the crank to fit I actually had to put the bearing carrier in the lathe and take off about .25mm on one face so the crank had clearance. So I err on the side of caution now so I dont have to pull it all apart to fix such aberrations.

Mal
mal - R69s
Toowoomba- Australia

User avatar
malmac
Posts: 501
Joined: Sun Jun 29, 2014 2:10 am
Location: Toowoomba, Australia.

Re: let the games begin - R69s engine rebuild

Post by malmac »

Been getting the bits ready to place the crank back into the case.

Good to be putting parts back together.
MAL_1300LR.jpg
Just dummied this up with the old bearing - just to show the press tool.
MAL_1302LR.jpg
Fitting the new camshaft gear to the camshaft.
mal - R69s
Toowoomba- Australia

User avatar
malmac
Posts: 501
Joined: Sun Jun 29, 2014 2:10 am
Location: Toowoomba, Australia.

Re: let the games begin - R69s engine rebuild

Post by malmac »

Installation of front timing gear onto crankshaft.

This was a bit of a test.
Did not have the factory wood-ruff key.
I had one almost the right thickness and one the right radius but too thin.
I used the linisher to get the thicker one to have the correct radius.
However it was still a little lose. It just slid away when I tried to install the gear.
So I TIG brazed one face and then carefully ground it down to get a .012mm interference fit.
To press it into the slot I modified a cheap "G" clamp.
Using tallow and 300F I was able to press the gear on finally.
MAL_1325.jpg
A - cut the face down to 6mm to press on the 5mm wood-ruff key.
B - cut an 8mm slot in the aluminium ring for the "G" clamp to apply force through gap.
C - machined out a 25mm cavity so the "G" clamp button would not slip off - nice neat press fit.
MAL_1324.jpg


Pressing in the wood-ruff key.
MAL_1323.jpg
Tools ready to fit on hot gear and press gear on.
MAL_1326.jpg
gear pressed onto crankshaft.
mal - R69s
Toowoomba- Australia

Daves79x
Posts: 460
Joined: Sun Aug 09, 2015 8:13 pm
Location: Knox, PA. USA

Re: let the games begin - R69s engine rebuild

Post by Daves79x »

Again, I admire your patience, but how hard or expensive could it be to just have gotten the correct key? I'm a meticulous guy, but I'd want to finish the bike before I died! Carry on.

Dave
Dave

User avatar
malmac
Posts: 501
Joined: Sun Jun 29, 2014 2:10 am
Location: Toowoomba, Australia.

Re: let the games begin - R69s engine rebuild

Post by malmac »

Daves79x wrote:
Sat Mar 06, 2021 7:45 am
Again, I admire your patience, but how hard or expensive could it be to just have gotten the correct key? I'm a meticulous guy, but I'd want to finish the bike before I died! Carry on.

Dave
Dave

I tried a couple of places for the right key but finally just wanted to put the engine back together.
Dont worry, I wasted a bit of time but the final fit was just as good as any bought key.

After adjusting the crank, the oil slingers, fussing with the oil pump gears, refacing the faces of the crankcase to ensure gaskets work well, putting in 12 blank inserts into the crankcase for the sump bolts, so no oil can leak out along the threads.... etc, etc ..... I am ready to get this engine back together before I die.

Thank you for taking the time to make suggestions..... it makes it worthwhile to post some updates.

Mal

Drilling one of the 12, 7mm holes which were then tapped to 8x1 for my custom blind inserts with a standard 6x1 internal thread.
MAL_1286.jpg
mal - R69s
Toowoomba- Australia

User avatar
malmac
Posts: 501
Joined: Sun Jun 29, 2014 2:10 am
Location: Toowoomba, Australia.

Re: let the games begin - R69s engine rebuild

Post by malmac »

Well the camshaft went in and the front gear cover is now in place.

Rear crank seal installed.

Cam followers installed.

Next job is to fit the oil pump pick up and fit sump.
Unfortunately then I have to put the project on hold for a a couple of months.
MAL_1332.jpg
Mal
mal - R69s
Toowoomba- Australia

flyingtpot
Posts: 42
Joined: Fri Oct 27, 2006 3:00 am

Re: let the games begin - R69s engine rebuild

Post by flyingtpot »

Mal, Looking and sounding really good on the build. Very soon, you'll be doing wheelies all over Toowoomba. :o :shock:

Ensure the lifters don't slide out and keep those rods from knackering the engine case.

User avatar
malmac
Posts: 501
Joined: Sun Jun 29, 2014 2:10 am
Location: Toowoomba, Australia.

Re: let the games begin - R69s engine rebuild

Post by malmac »

flyingtpot wrote:
Fri Mar 12, 2021 10:12 pm
Mal, Looking and sounding really good on the build. Very soon, you'll be doing wheelies all over Toowoomba. :o :shock:

Ensure the lifters don't slide out and keep those rods from knackering the engine case.
thanks for the heads up.

after this pic was taken, i plugged the lifter bores with lint free cotton and also inserted wooden con rod holders. so i think i have it covered unless i misunderstood your message.

mal
mal - R69s
Toowoomba- Australia

User avatar
malmac
Posts: 501
Joined: Sun Jun 29, 2014 2:10 am
Location: Toowoomba, Australia.

Re: let the games begin - R69s engine rebuild

Post by malmac »

A forced break while I did other projects, nothing to do with my old bikes.

Finally got around to torquing down the flywheel.
I followed the Barrington book and measured the runout at regular intervals.
Final figure .04mm runout.

A few new bits went into the clutch.

Here is my setup for holding back and measuring runout.
MAL_1427.jpg
Installation of the clutch.
MAL_1430.jpg
mal - R69s
Toowoomba- Australia

User avatar
malmac
Posts: 501
Joined: Sun Jun 29, 2014 2:10 am
Location: Toowoomba, Australia.

Re: let the games begin - R69s engine rebuild

Post by malmac »

Heading for 14 months for this project and given other obligations it will be some time before I can carry on from here.
However, the new pistons and barrels went on today and it was a boost to morale that things are progressing.
A couple of pics to show the progress.
MAL_1432.jpg
MAL_1433.jpg
MAL_1436.jpg
mal - R69s
Toowoomba- Australia

Post Reply