Two weeks it has taken to remove two inlet guide retaining rings, pretty sad.
4 broken tools including Robert Watson’s special bespoke unit.
Thankfully I was able to reclaim Robert’s by milling new tangs (big apology Robert).
The KTB gives a detailed drawing of the tool (Fig 11, page 119) – and instructions are to use high tensile steel, ie an old car half shaft. I didn’t have an old car half shaft on hand, being a motorcycle shop, but I did find half of a Norton gearbox main shaft.
I was able to machine the extact tool, with milled tangs and internal thread on both ends.. Trail fit, ok, heated the head, installed the tool, tightened centre bolt, ready to undo… and snap, both tangs broke off – maybe not high tensile after all.
Decided another approach would be required, I machined a piece of ¾” HRS with 3/8” BSF thread on inside and 2 flats for a 5/8” wrench on the other end.
I laid out the dimensions and drilled 2 x 1/8” holes and hammered in some cut off HSS drill bits and shaped them square-ish with the Dremel.
Same, process, same result, bent and sheared off.
Since the broken pieces were still in the tool, I had to lay it out again and drill 2 more 1/8” holes.
I found some 1/8” carbide bits that were cut off, shaped and installed …. they worked! Eureka!
What a process.
Now I still have to shorten the top of guide by top cutting and machine the brass retainer ring for the oil seal.
24 hours sounds about right for this operation? … no wonder these engines cost so much to rebuild.
4 broken tools including Robert Watson’s special bespoke unit.
Thankfully I was able to reclaim Robert’s by milling new tangs (big apology Robert).
The KTB gives a detailed drawing of the tool (Fig 11, page 119) – and instructions are to use high tensile steel, ie an old car half shaft. I didn’t have an old car half shaft on hand, being a motorcycle shop, but I did find half of a Norton gearbox main shaft.
I was able to machine the extact tool, with milled tangs and internal thread on both ends.. Trail fit, ok, heated the head, installed the tool, tightened centre bolt, ready to undo… and snap, both tangs broke off – maybe not high tensile after all.
Decided another approach would be required, I machined a piece of ¾” HRS with 3/8” BSF thread on inside and 2 flats for a 5/8” wrench on the other end.
I laid out the dimensions and drilled 2 x 1/8” holes and hammered in some cut off HSS drill bits and shaped them square-ish with the Dremel.
Same, process, same result, bent and sheared off.
Since the broken pieces were still in the tool, I had to lay it out again and drill 2 more 1/8” holes.
I found some 1/8” carbide bits that were cut off, shaped and installed …. they worked! Eureka!
What a process.
Now I still have to shorten the top of guide by top cutting and machine the brass retainer ring for the oil seal.
24 hours sounds about right for this operation? … no wonder these engines cost so much to rebuild.