{"id":3946,"date":"2016-02-16T18:58:08","date_gmt":"2016-02-16T08:58:08","guid":{"rendered":"http:\/\/wordpress.cpc-world.com\/?page_id=3946"},"modified":"2016-10-20T19:47:11","modified_gmt":"2016-10-20T09:47:11","slug":"build-actual","status":"publish","type":"page","link":"http:\/\/pietenpol.cpc-world.com\/?page_id=3946","title":{"rendered":"Build – Actual"},"content":{"rendered":"

Rather than give a blow by blow account of my engine rebuild go to Mark Langford’s excellent website<\/a> and follow his rebuild from there. I will show some pictures of my rebuild with some additional comments.<\/p>\n

Rather than build the engine in the shop along with the sawdust, I decide (with permission!!) to start the rebuild in the kitchen. I first bolted both crankcase halves together with the crankshaft and camshaft complete with new bearings.<\/p>\n

\"IMG_0630_JPG\"<\/a>Crank & Cam installed.<\/p>\n

\"IMG_0637_JPG\"<\/a>With No.1 cylinder at TDC the camshaft and crankshaft keyways aligned as shown, together with the marks on both camshaft and crankshaft should mean that it’s all OK!<\/p>\n

\"IMG_0635_JPG\"<\/a>Right-hand bank cylinders and cylinder head in place.\"IMG_0640_JPG\"<\/a>Both banks installed. I still have to torque the rod bolts<\/p>\n

\"IMG_0646_JPG\"<\/a>Getting in to torque the rod bolts. I used a beam torque wrench and a standard 1\/2 inch socket.<\/p>\n

\"IMG_0653_JPG\"<\/a>Rear of rebuilt engine.<\/p>\n

\"IMG_0654_JPG\"<\/a>Front of rebuilt engine.<\/p>\n

\"IMG_0663_JPG\"<\/a>With alternator and starter motor fitted.<\/p>\n

\"IMG_0667_JPG\"<\/a>Alternator and starter motor detail (front).<\/p>\n

\"IMG_0669_JPG\"<\/a>Alternator and starter motor detail (rear).<\/p>\n

\"IMG_0674_JPG\"<\/a>Some old waste pipe being used as the inlet manifold pattern. I intend having some aluminum tubing bent to shape. I am hoping that I can weld the bend to the flange rather than have the ‘tee’ piece as shown.<\/p>\n

\"IMG_0675_JPG\"<\/a>The right side….<\/p>\n

\"IMG_0673_JPG\"<\/a>…and the rear view.<\/p>\n

\"IMG_0677_JPG\"<\/a>The carb will mount approximately where the two hose clips are on the bottom tube.<\/p>\n

\"IMG_0752_JPG\"<\/a>I moved the engine to the engine mount and fitted it to the fuse to check the fit of the manifold. Needs a couple more aluminum bends and some more welding but is looking good so far.<\/p>\n

\"IMG_0753_JPG\"<\/a>The inlet manifold in its final (approximate) position.<\/p>\n

\"IMG_0755_JPG\"<\/a>The carb mounted in position.<\/p>\n

\"IMG_0775_JPG\"<\/a>The engine test frame awaiting the engine.<\/p>\n

\"IMG_0776_JPG\"<\/a>I changed out the original Nippon Denso alternator for a John Deere unit.<\/p>\n

\"IMG_0782_JPG\"<\/a>The gives a much cleaner profile and I can now get efficient cooling on both cylinder banks with properly positioned cowling “ears”.<\/p>\n

\"IMG_0780_JPG\"<\/a>Top bracket details still waiting for some paint.<\/p>\n

\"IMG_0781_JPG\"<\/a>The bottom bracket bolt will be changed for the correct length!<\/p>\n

\"IMG_0800_JPG\"<\/a>I changed out the mounting bracket to an aluminum plate. I need to fit the tacho sender on the other side of the engine so I took the opportunity to make the brackets the same type. I borrowed the idea from William Wynne’s website.<\/p>\n

\"IMG_0806_JPG\"<\/a>Shows the side on view of the new bracket\"IMG_0804_JPG\"<\/a>The tacho sender unit mounted close to the starter ring gear<\/p>\n

\"IMG_0805_JPG\"<\/a>The sender half a turn back from the starter ring gear.<\/p>\n

\"IMG_0832_JPG\"<\/a>The inlet manifold welded together<\/p>\n

\"IMG_0837_JPG\"<\/a>The HD CV40 Carburetor mounted in position.<\/p>\n

\"IMG_0853_JPG\"<\/a>I modified the alternator mounting bracket to accept the oil pressure and temperature senders.<\/p>\n

\"IMG_0855_JPG\"<\/a>The Port side exhaust system mounted in position. Needs a coat of High Temp paint.<\/p>\n

\"IMG_0858_JPG\"<\/a>The engine with both test “Ears” attached.<\/p>\n

\"IMG_0859_JPG\"<\/a>Ready now for the carb heat air box\/air filter.<\/p>\n

\"IMG_0889_JPG\"<\/a>Ready for its first start-up!. (Click on the images to hear the engines first run.)\"IMG_0920_JPG\"<\/a>I modified the stand to make it easier to manage. (Click here to see why!!)<\/p>\n

I have found that the Harley Davidson CV 40 Carburetor needs priming or full choke at each start up. If I put my hand over the carb mouth at start up it fires up OK. As soon as the prop blast hits the carb when I remove my hand the engine dies. Too much air I think. I will make up a choke as part of my air box to see if that helps with the starting. I think I need only the choke or primer, not both. Ignition is set to about 8 degrees so should give me about 30 degress when WOT. I also intend making the ears smaller in height so that they fit within the cowling. I also find that the starter motor doesn’t like anything except a fully charged battery. The starter motor jams sometimes if not fully charged. Could be some tuning on the timing is required.<\/p>\n

\"IMG_1013_JPG\"<\/a> \"IMG_1012_JPG\"<\/a> \"IMG_1011_JPG\"<\/a>Changing the timing improved the starting considerably. I also installed an Odessy Battery which has not needed charging. I have changed the carb out for a borrowed NAS-3. I also borrowed a three blade prop and the combination is working very well. Presently the engine turns static at around 2800rpm. Oil pressure is in the 45 – 50 psi , the oil temp and CHT not very high (too much cooling with no cowling?) I am thinking of purchasing a NAS-3 or MA3-SPA. The CV 40 is OK but needs a lot of adjustment and fiddling about. The NAS-3 bolted straight on with (at present) no adjustment needed. Click on these small images for some engine runs. These runs are with the CV 40 still installed<\/p>\n","protected":false},"excerpt":{"rendered":"

Rather than give a blow by blow account of my engine rebuild go to Mark Langford’s excellent website and follow his rebuild from there. I will show some pictures of my rebuild with some additional comments. Rather than build the engine in the shop along with the sawdust, I decide (with permission!!) to start the […]<\/p>\n","protected":false},"author":1,"featured_media":0,"parent":0,"menu_order":0,"comment_status":"closed","ping_status":"closed","template":"","meta":{"footnotes":""},"class_list":["post-3946","page","type-page","status-publish","hentry"],"_links":{"self":[{"href":"http:\/\/pietenpol.cpc-world.com\/index.php?rest_route=\/wp\/v2\/pages\/3946","targetHints":{"allow":["GET"]}}],"collection":[{"href":"http:\/\/pietenpol.cpc-world.com\/index.php?rest_route=\/wp\/v2\/pages"}],"about":[{"href":"http:\/\/pietenpol.cpc-world.com\/index.php?rest_route=\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"http:\/\/pietenpol.cpc-world.com\/index.php?rest_route=\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"http:\/\/pietenpol.cpc-world.com\/index.php?rest_route=%2Fwp%2Fv2%2Fcomments&post=3946"}],"version-history":[{"count":0,"href":"http:\/\/pietenpol.cpc-world.com\/index.php?rest_route=\/wp\/v2\/pages\/3946\/revisions"}],"wp:attachment":[{"href":"http:\/\/pietenpol.cpc-world.com\/index.php?rest_route=%2Fwp%2Fv2%2Fmedia&parent=3946"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}