Happy Christmas every one and I hope your projects continue well in 2015.
You know its absolutely great to be back to to a cold damp Wales. I definitely know I am back as in the Indian restaurant last night a drunken reveller came in for dinner with his Husky called twilight insisting a curry and rice for him and papadams for the dog. I can also log on to access norton again. Its strange that access is banned in China and Africa, (West and North), both areas where I work.
I was in Casablance and spent a very memorable evening with a bottle of wine cleaning this:
and using a toothbrush for what seemed like hours getting it to this
... this was my first job that I have now fitted back into the frame. And who said you had to start your rebuild with the horn LOL...
Well my 850 is coming along well. Frame and cycle components have all been stripped and sprayed. All are lovingly wrapped in cardboard and bubble wrap. I have decided to spray the tannk and side panels last, and I have pressure checked the tank for leaks and stripped the tank and panels bare. With a rough coat of undercoat I will leave them until all other work is completed,
On fully stripping the engine I found that the cam lobes were stepped (so am purchasing a new cam, and maybe one with a longer valve duration). This means machining the pistons and part of the crankcase I am told. So parts are in the machine shop to do this.
You can see the step on the camshaft lobes here:
The engine itself has been in surprisingly good order, although one of the crank bearings seems to have rotated in its housing. It shows scratches on the outside and so I will definitely change it.
The crank itself is fine with no signs of any damage or wear, much to my surprise seeing the conditions this bike was ridden in, and so will be used as-is as it has had a good clean up and thorough check.
I have had the damaged fins repaired by a specialist welder and the whole cylinder assembly has been stove enamelled black.The top of the cylinders have been skimmed flat by a specialist and I just need to glaze bust the bores and refit the pistons once the valve pockets are machined into them. I must say I am very pleased with the results on the engine cylinders, they really look brand new.
The crank cases have been stripped ban and bead blasted. I was so pleased as they have come up as new:
It has taken hours to clean out every bead hidden in the crevices of the cases, even though many were blocked up before bead blasting began.
I now have to polish out a deep scar on the timing cover and then bead blast this clean. That is my first job in 2015, so looks like I will be travelling back to work with my trusty polisher in my hand baggage.
The valve guides are being replaced, but fortunately the valves were fine and will be re-used.The head will then be ready for re-assembly, with new bolts.
The cylinder head has been bead blasted and again has come up like new:
Well guys that all I have managed to do for 2014 on my project....have a great Christmas and 2015...... see you soon, and more regularly so if I can upload from foreign climes....