Detroit 6/71 - Work required

[Divemaster1]

Yet another painful update .... and you wanted to hear all the issues encountered...

Cylinder Liner #5 was a pain to remove ... took me the best part of two hours on Saturday ... and once out it was clear why.. Carbon deposits on the outside trough a crack in the liner.... reasons for I do not know, but once carbon deposits on piston was getting cleared off, it became clear that this is an "ex-piston" with split top compression ring, and deformation (stress fatigue) on crown above the failed piston ring..

Top inspected and getting cleaned, and perhaps surprisingly enough, no damage to valves etc... so at least something is going my way....

So another piston and liner on order ... .... Total cost £300.55 incl VAT ... so now fictive budget blown with approx. £350 .... or £58 per cylinder...

Good news include that I have assembled and torqued up nearly all additional parts that was loosened off to gain access to the fwd part of the engine..., so parts, nuts & bolts in containers are reducing.....

 

[Divemaster1]

For those wondering, we have bee quiet for a couple of weeks due to personal circumstances which did not include anything remotely boaty...

This week-end I was back into swing and last new cylinder liner was inserted with the new piston on Saturday. On Sunday, the 110 Kg cylinder head was moved into position, lifted, lowered, pulled forward and tilted 45 degrees, and pulled into position. The latter part here was always going to be challenging as I only have about 1 mm clearance between fwd and aft part of the block... This means that the cylinder head needs to be lowered and pulled into the 45degree slanted block in-line and also equally lowered at the same time fwd and aft, whilst not disturbing the water jacket, oil passage and cylinder head seals. Slow, steady, constantly checked etc., made the cylinder head slot into position with bolts all torqued up to 240 NM after a long, painful 5 hr operation. now on a home run, and "only" have exhaust manifold, water manifold, governor (and controls), after-cooler, turbo, alternator, oil-pan access hatches etc., to install before filling her up with liquids, doing a tune-up and going for that anxious moment of turning her over for the first time again... pictures from this week-end's lifting operation will follow tonight ...

 

[sharpness]

Glad your on the home run Alf. If your manhandling 110kg lumps of metal, I reckon your new nickname should be Popeye

 

[Divemaster1]

So here we go with pictures of the lifting job;

Lifting bar in place;

Half way down before shifting forwards and tilting 45 degrees ... after this was taken lifting points was made through the fwd hatch and gradually made to take the strain, before tying a rope to the port side of the cylinder head ... keeping this in situ and lowering the rest until at approx. 45 degrees..

An here in situ where you can see the lower part of the cylinder head slid in to the fwd and aft section of the block...

Relatively happy camper as this took some time due to very tight space for the block... but now on a more predictive path for completion whilst nursing some of my bruises...

 

[rafiki_]

Great job Alf.

 

[davids0865]

Well done Alf, nearly there now. It has been a bit of a saga hasn't it

Does that type of ratchet strap allow you to lower under control?

 

[Divemaster1]

..............Does that type of ratchet strap allow you to lower under control?

Nope.... made it a bit more interesting ... and hence the ropes ...

Basically lowering on ropes, with ratchet strap being the security to take strain when lowered to a point of ratchet strap taking strain ... and then checked, moved forwards, tilted and lowered again...

 

[davids0865]

OOOOOH fun fun fun Must be good to see the end in sight.

 

[Divemaster1]

Pieces getting together now, with pieces disappearing down into black hole...

Alternator (now with new fan-belt)
Exhaust Manifold
Governor
Exhaust Jacket water Manifold
Turbocharger
Oilpan Access Hatches (2x off)
Crankcase Breather
Half the fuel pipes...

Next WE will hopefully see installation of;

After-cooler
Fuel Rack & governor connectors
Rest of fuel pipes

Fill up of Liquids ..

23 L Oil
32 L Coolant

Then Valve Clearances, Injectors and back off idle and vent fuel system in prep for first turnover to build up oil pressure before start-up (hopefully) and idle setup...

Then on to some cleaning and on to finishing heads refurb.....

 

[vas]

Next WE will hopefully see installation of;

After-cooler
Fuel Rack & governor connectors
Rest of fuel pipes

Fill up of Liquids ..

23 L Oil
32 L Coolant

Then Valve Clearances, Injectors and back off idle and vent fuel system in prep for first turnover to build up oil pressure before start-up (hopefully) and idle setup...

Then on to some cleaning and on to finishing heads refurb.....

nice,

So what, a couple of hours work and you're ready for a drive, right?


cheers

V.

 

[Divemaster1]

nice,

So what, a couple of hours work and you're ready for a drive, right?


cheers

V.

Depends on how you count the hours..... if you're like me, then "a couple of hours" usually runs into the full day...

 

[AndieMac]

Well you certainly can't be accused of rushing the job Alf all this had better work you know!

Have you got a cruise organised for the summer?

 

[Divemaster1]

LOL... you try to single man-handle (safely) items like the 40 Kg exhaust manifold (double layer casted, with water jacket), into position, avoid damaging stuff and without interrupting seals etc... this stuff takes time ... of course there have been a couple of distractions ... such as Mother's heart valve operation (time with family) and our pet (cat) of near 16 years, having a bad diagnosis, and spending some time with him before taking him to the Vet one final time (RIP Oliver), daughter at uni etc.... all takes time away from WE on boat...

And yes, I will be crossing my fingers when I turn that key around ....

Plan is to cast off and have the last two weeks in July heading Westwards... no planned destination, which is part of the joy!!

 

[vas]

Depends on how you count the hours..... if you're like me, then "a couple of hours" usually runs into the full day...

I'm sometimes worse, a couple of hours could be a couple of days!

cheers

V

PS. Btw, looks like I'm going to be in Greece when you come, got to check again your plans and PM you (probably during the w/e)

 

[AndieMac]

And yes, I will be crossing my fingers when I turn that key around ....

Plan is to cast off and have the last two weeks in July heading Westwards... no planned destination, which is part of the joy!!

How about setting up a video camera so we can all share the moment when the mighty DD's roar back into life again Alf.

Hope you are planning to compile an epic cruise report during the West Coast cruise as well sir! :encouragement:

 

[Divemaster1]

How about setting up a video camera so we can all share the moment when the mighty DD's roar back into life again Alf.

Hope you are planning to compile an epic cruise report during the West Coast cruise as well sir! :encouragement:

Can feel the pressure already ... .. .. will record, but not broadcast live .... just in case I missed a part or two

Let me finish the head re-furb first, then we can look at building a cruise report ....

 

[Divemaster1]

No other comments than "it's alive" !!

http://s166.photobucket.com/user/As...jects/VID-20140615-00002_zpscaf37a24.mp4.html

After cooler, Control cables, Electrics, Liquids (Oil & coolant), Valve Clearances, Injector timing, fuel system prime, lube circulation with idle completely backed off (to no fuel).... and check of nuts & bolts ... before letting her fire .... then a quick set of idle before the 1 min video...

Now for the last pieces (rocker cover etc.) ... then clean-up before moving on to the heads refurb....

 

[vas]

well done Alf,
tbh, I thought that it would take you much longer to fire her up, so a bit shocked it all happened so quickly!

btw, how are rockers and co lubricated? I'd have thought with no rocker cover on there would be lots of oil spray everywhere. Is it oil fumes it works on?

cheers

V.

 

[Divemaster1]

Thanks Vas .... started her up without rocker cover to observe fuel rack and having an additional way of pulling to zero fuel ..... and yes oil spray everywhere!!!

 

[Robg71]

Thanks Vas .... started her up without rocker cover......... and yes oil spray everywhere!!!

Theres a suprise

Glad its all back together and gone to plan