POTD- PROJECT OF THE DAY: What Did You Make In Your Shop Today?

GoceKU said:
Today was judgement day for the K7M engine. It's not making compression, the starter motor got a good work out but wouldn't start. After thinking about it i decided i'll rebuild it in place. i have one more spare but if this one is stuck i'm sure it will be also. With only 2 hours to spare i took apart everything around the top end and managed to remove the cylinder head. The engine is much cleaner inside the cylinders than the rest of the engine, some one did not changed there oil on time. This engine has 136 000 km and as you can see the valves are like new , i haven't clean them or the pistons. Tomorrow i plan to get the oil pan out and remove the pistons also i'll take apart the cylinder head it needs a good resurface, valves ground, new valve seals. Working on a petrol engine is much easyer then diesel.
View attachment 395715View attachment 395716View attachment 395717
Click to expand...

Is it just me, or is there damage to the intake on valve Cyl1, and exhaust Cyl2? Might be lighting in the image...
 
This morning i had few hours before work so i got to work, took apart both cylinder heads, one from this engine and the one from the original( one that i changed). Then come the hard part taking off the oil pan, oil pump and all 4 pistons. The crank and bearings look like new, the pistons are very dirty and the piston rings are stuck solid, nothing broken but i have lots of cleaning. I took both cylinder head with me to work and on my way back i'll stop by my friend to get them resurfaced. The machine shop that used to bore engines, resurfaces them closed up forever.
IMG_20220207_120311.jpgIMG_20220207_120319.jpgIMG_20220207_120323.jpgIMG_20220207_135828.jpgIMG_20220207_135836.jpgIMG_20220207_135858.jpg
 
GoceKU said:
That is oil spots the valves are OK.
Click to expand...
Ahh, OK.

I'm used to looking at brand new engine parts. Sometimes we see parts that were run, but always cleaned up before we see them...
 
dkemppai said:
Ahh, OK.

I'm used to looking at brand new engine parts. Sometimes we see parts that were run, but always cleaned up before we see them...
Click to expand...
You can see the difference, the yellow box has the valves from the "new"(136K) engine the red box has the valves with (257K)on them.
IMG_20220207_120319.jpg
 
Benchtop bandsaw table done!

Cut off the excess tubing and painted with semi-gloss black and orange border. I know it looks red in the photo but it is actually orange.

IMG_4395.jpeg

IMG_4398.jpeg

I also installed a 2"x2" plastic cap to avoid dirt/grit to get inside the tube…

C3AFF94A-F931-414F-A3F4-B66F0CF8F8C4.jpeg
 
Last edited:
After work i stopped by my friends shop he has a decent size mill, so he resurfaced the cylinder heads for me. He used a shop made a fly cutter with diamond inserts at 400 rpm at different feeds, the finishing pass was at 0,04 mm the finish is like a mirror. One of the head was bent like a banana, but with 0,48mm of the surface cleaned up.
IMG_20220207_120304.jpgIMG_20220207_120323.jpgIMG_20220207_190822.jpgIMG_20220207_191531.jpgIMG_20220207_193814_1.jpgIMG_20220207_215331.jpg
 
Got a set of short counterbore metric bits… and first time using the ER20 collect setup…

6BAEBE8A-D7F7-4D95-8C4D-B4DF3C518B2C.jpeg
The task at hand was to ensure everything was concentric… When I initially did these holes, these were made manually as I did not have counterbore bits.

With this done, I was able to dial in the 4-jaws chuck on the 9”x20” lathe!! Woohoo! I know it is a photo... a video of me turning the chuck and seeing that the caliper stays still (well... .0005" movement) would have been better...

IMG_4407.jpeg

Next…to turn the hex rod into a key for the 5-C collect chuck….

7A53484C-1410-4882-9DAB-15797E52090D.jpeg
 
Last edited:
You must log in or register to reply here.
Back
Top