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tea boy

Tea Boy's Massive Rod

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Yay JJ’s!

I’ll let you know when I hear anything about reopening.

It’s not that posh Nige. 😀

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This is their FB page, it must be a bit posh because the lovely Doctor Julia is on there, along with some slightly less desirables.

93-C4481-E-7-EC2-4-B81-B581-2-AB44000-D9

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To take my mind off the oil tank I have decided that I might have a look at this.

E601-CEE5-591-F-48-F2-9716-0-A50184-DE61

I've got a few bits and bobs to mess about with.

8971-E499-895-D-4-C1-D-B7-A1-DB9-F6-C0-F

I've started cleaning things up but it's hard going.

B8-A16894-82-CF-4599-A75-F-9-FE1283-D0-D

Polished the valves.

495355-F2-E372-45-FD-A5-FF-CFA59666-E57-

Most of them are ok but I need to replace a couple of exhaust valves.

I've taken the studs out of the case and cleaned them up to get them replated along with some other bits of hardware.

0-F863-B88-7-D4-B-41-B2-8821-CA4-F246711

6-B211-B73-1208-43-D3-B6-B9-E8509-CFD477

I drew a map so I know where all the studs go when they come back.

D4-DDC203-6-CA1-45-CB-BAB0-B71-A1-E65-E8

I think I'm going to get a few bits vapour blasted and as they charge by the hour I thought I'd better clean them up as best I can first.

C0383817-9-AF9-4-F8-A-B132-30-F18-BAEFEB

I've also stripped down the fan/alternator assembly, I'm not sure what finish I'm going to use on the fan yet but it might not stay hearing aid beige.

71-E5-F8-AC-A405-4596-A85-D-B2-E7-ACA6-A

What do people use on the fans?

I'm not going to powder coat it that's for sure because I don't rate it at all.

 

 

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Brilliant, I am in for a JJs trip. Miles away though it is...

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2 hours ago, johndglynn said:

Brilliant, I am in for a JJs trip. Miles away though it is...

Yay JJ’s!

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Posted (edited)

The fan is stripped down, the housing needs a bit of a tidy up.

6911738-A-0544-4-D5-C-ADD3-204537183037.

Whilst it was out I thought I should take a look at the alternator.

5-B6-ACAF3-CA6-F-4496-A970-BDB0-CD32-D94

There was a fair old trench in the slip rings.

4-E758-D46-B860-4-A40-AFF3-6-AA53-ADC838

They started life at 28mm but are now 26.47mm.

C01-CC615-81-A8-476-D-A23-D-A4823-CF1-B5

That was a bit too much for my liking so I got a replacement.

690-D2-B0-F-E6-CF-4-A1-D-BC69-9-EA457-B8

The bearing needs to come off first, obviously.

84-E6-C3-A0-295-F-46-AD-81-A1-7-ECF02-FB

Then the old rings can come off.

0607-F96-E-F04-E-4120-9-AE4-8633-A6-DA2-

I tapped the new ones on with a suitable piece of tube. I did get tap happy and ended up 0.3mm too far down the shaft but it will be fine.

E1-BDC7-ED-B40-D-438-D-8389-576-AC72-A34

Then all you have to do is solder on the two wires, piece of cake.

These wires. Top

0767635-F-557-C-429-C-A693-1-D90221-F194

Bottom.

A2-DB9-B8-D-AD8-B-4967-B136-5-A018-FE57-

I have a 100 Watt soldering gun but it couldn't get the job hot enough to solder the wires on, the slip rings were just sucking up the heat.

I tried pre-heating it but it didn't really help.

What I needed was more Watt.

I ordered a cheap Chinee 300 Watt soldering iron off eBay.

I was quite surprised when it turned up, the thing is massive.

32040-A3-A-BDA1-4-B83-B518-E5-F1-E5-AA9-

The tip is like a shovel.

38666-FAA-F0-CA-4716-A4-FC-893-AAFA3535-

It's not really a precision instrument but it did the job.

CAEB43-AD-1131-4-F12-9646-670-D4-B2-C778

Then it was just a case of tidying it up on the lathe and making sure that the rings were concentric to the shaft.

It needed 0.25mm removing to true it up so the finished size is 27.75mm.

Once it was trued up they got a quick polish up with 2000 grit.

CA33-B752-0-F9-B-4-F91-8553-63-EB78596-A

I got some new brushes to go with them.

The brushes come with the voltage regulator.

I went with a Beru reg because it is a good German brand and was much cheaper than Bosch.

 A556589-C-AEB2-45-FE-89-E6-F929-ACA766-E

Despite the German address on the box it was made in..

7-D0-C0-D3-F-5569-41-B9-8524-AFB4983-E9-

I'm still waiting for bearings so that's as far as I can go with that bit.

I did tidy up the field coils despite them being totally out of sight when assembled.

7-A7448-DC-5-EF2-438-E-8-EDA-EFF676-B360

The red oxide was just about a perfect match for the original but the matt finish was not.

Luckily I keep a tin of high temperature lacquer in the cupboard under the sink for just such occasions.

110-F2-FA3-FF24-4-F88-97-F0-3189-FB2098-

The rear bearing is held in the case by a plastic retainer.

The old one looked a bit brittle so I got a replacement.

E6-BC39-BB-6-DF3-4186-BABD-3-C05-E687234

According to the picture on the packet I'm going to need a hard hat, bib and braces and an absolutely huge spanner to fit it.

 

Edited by tea boy

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Posted (edited)

Proper fettling that. Great work 👍

Edited by Busybee
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On 14/06/2020 at 00:16, tea boy said:

To take my mind off the oil tank I have decided that I might have a look at this.

E601-CEE5-591-F-48-F2-9716-0-A50184-DE61

I've got a few bits and bobs to mess about with.

8971-E499-895-D-4-C1-D-B7-A1-DB9-F6-C0-F

I've started cleaning things up but it's hard going.

B8-A16894-82-CF-4599-A75-F-9-FE1283-D0-D

Polished the valves.

495355-F2-E372-45-FD-A5-FF-CFA59666-E57-

Most of them are ok but I need to replace a couple of exhaust valves.

I've taken the studs out of the case and cleaned them up to get them replated along with some other bits of hardware.

0-F863-B88-7-D4-B-41-B2-8821-CA4-F246711

6-B211-B73-1208-43-D3-B6-B9-E8509-CFD477

I drew a map so I know where all the studs go when they come back.

D4-DDC203-6-CA1-45-CB-BAB0-B71-A1-E65-E8

I think I'm going to get a few bits vapour blasted and as they charge by the hour I thought I'd better clean them up as best I can first.

C0383817-9-AF9-4-F8-A-B132-30-F18-BAEFEB

I've also stripped down the fan/alternator assembly, I'm not sure what finish I'm going to use on the fan yet but it might not stay hearing aid beige.

71-E5-F8-AC-A405-4596-A85-D-B2-E7-ACA6-A

What do people use on the fans?

I'm not going to powder coat it that's for sure because I don't rate it at all.

 

 

I had mine (and the housing) aqua blasted to get them cleaned up, rattle canned the fan with a couple of light coats (you can choose your own colour!) then some clear polyurethane rattle can on both to add some durability.

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6 hours ago, Fuchs915 said:

I had mine (and the housing) aqua blasted to get them cleaned up, rattle canned the fan with a couple of light coats (you can choose your own colour!) then some clear polyurethane rattle can on both to add some durability.

I’m going to get a few bits vapour blasted when I get the opportunity to drop them off.

The housing is going to be chromated, not sure what I’m going to do with the fan yet.

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I've got a dodgy elbow, I've no idea how I've done it because I can't play tennis to save my life.

I didn't help it at all today because I decided to remove my old cylinder head studs.

They were well glued in.

I tried to lock two nuts together to wind them out but that just wouldn't work so I resorted to the stilsons and a heat gun.

E632-EE3-E-4-B35-4331-A4-D1-2-A5-D44-AB1

I have got some really top quality Snap-On and Rigid stilsons but they were all too big so I resorted to the ones my dad got me from Lidl.

He doesn't know anything at all about tools, besides what he knows about me, of course, but they did the trick.

My elbow is really hurting and I have also gained a few blisters on my fingers and a bruised palm but the things are now out.

5-CB2-FFFF-D367-407-F-9-A59-F072-C7802-A

Due to a couple of total disasters, not car related, which I won't bore you with here, that's all I managed to get done on it this weekend.

 

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14 minutes ago, Ian Comerford said:

Nice job.  What type are you replacing them with?

The latest spec 993 dilavar.

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I think that’s a good choice, although if you read too much on Pelican it gets a bit like the best oil/tyres debate.....

  • Haha 1

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1 hour ago, Ian Comerford said:

I think that’s a good choice, although if you read too much on Pelican you go blind it gets a bit like the best oil/tyres debate.....

:whistling:

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11 hours ago, Ian Comerford said:

I think that’s a good choice, although if you read too much on Pelican it gets a bit like the best oil/tyres debate.....

My logic was, why would Porsche have persisted with developing different versions of the dilavar stud if they could have just used steel ones instead.

The counter argument is that having gone to the trouble of developing it they didn't want to lose face by saying actually, no you don't need these after all.

The ones I took out were the previous type factory studs and none of them had broken.

I don't know what's best for sure, but it feels like the right way to go.

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Just use some threaded bar as by the time you finish the oil tank the Earth will have engulfed by the sun.

  • Haha 3

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2 hours ago, Ian Comerford said:

And on that point, when are we going to JJ's?

Yay JJ’s!

 I think we’ll have to wait until they reopen.

I’ll keep everyone in the loop.

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haven't been on here for years and the first thread I see is about your bloody oil tank!!!! It's like I've never been away 😆😆😆

 

Great work Tea!

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I managed to drop a few bits off at the vapour blasters the other day.

He tidied up the alternator casings whilst I was there but I left the rest with him.

93-FEF80-F-8800-43-D9-9-FF1-F37-E989-E6-

A reminder of what they were like.

5-B6-ACAF3-CA6-F-4496-A970-BDB0-CD32-D94

With the repainted field coil it looks ok I think.

E1-E77-FDA-9-ACF-47-C3-B78-D-B3-D8-D94-A

I've still got some messing around to do on the crankcases.

The pressure relief valve piston was stuck in the hole.

It's the upper one of these two holes.

8-DF9-A6-D3-96-F6-4-C36-BFF1-084-F2-AFBA

I had a cuppa and a bit of a contemplate on the best way to get it out and came up with a 12mm OD sleeve anchor bolt.

E07100-F7-6-D2-D-4522-B394-E525-A0-E5326

Which luckily did the trick.

441108-B9-FEA9-4-DD1-8-D79-0-B92-FFDE3-F

I need to get the piston squirters out because they look a bit dodgy.

Some look like this.

8-EC60-BF2-A70-F-4-A7-A-A724-BCDD288-B50

While others seem to have sunk.

06-F7089-C-C0-E1-425-C-9-B24-5-C07-CF2-E

I think I'm going to replace them with some of these.

7-BCDE2-E2-FFB3-407-F-B424-1-E2-B85-CA38

Oh, started making a top baffle for the oil tank...

F1532-CB5-2-D63-4-C24-AC18-65-BEC129-F05

 

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