Taking time off to work on the boat

[tico]

Piece of steel strip approx 50mm wide x 5mm thick
Cut a 'U' shaped slot in one end to suit the piston rod
Drill & tap 4x m5 holes to suit the holes in the cylinder end cap
fit 4x m5 capheads through so as to protrude approx 5-6mm
Chamfer the inside of the 'U' slot to give clearance for the cylinder scraper seal.
Job done

 

[petem]

Although I can replace the end caps they have corroded very badly i.e. the C spanner holes are now worthless and it would probably need drilling, cutting, then collapsing the end cap to get it out. No professional wants to undertake the job because of the risk to damaging the cylinder even though I tell them it makes no odds, that I'd have to replace them if they didn't do the job anyway.
That leaves me thinking that this is probably then a job I shouldn't willingly undertake myself.

Has anybody successfully collapsed an endcap using this method? DP-D with 3860881 rams

Fixed it yet Bruce?

 

[BruceK]

Not yet I am going to try and replace them as they are aging. I am pretty sure I can do it without lifting the engines and so do it myself. So I have ordered in some tools. My plan of action is first to use a grease gland cleaner, which is much like a grease hammer except instead of grease I will knock Plusgas penetrating oil through to lubricate. I have also got a 10 000 psi grease gun and a grease hammer to push the pins and will create a puller for the front with a HT bolt through a penny washer and socket. If those dont loosen it I will cut the ram eye off and and add manual persuasion to the pin by twisting it while under pressure and adding more penetrating oil to the forward part of the pin. And if that fails there is always my chainsaw Wish me luck. Better yet, wish me patience. Those pins will come out!

 

[petem]

Not yet I am going to try and replace them as they are aging. I am pretty sure I can do it without lifting the engines and so do it myself. So I have ordered in some tools. My plan of action is first to use a grease gland cleaner, which is much like a grease hammer except instead of grease I will knock Plusgas penetrating oil through to lubricate. I have also got a 10 000 psi grease gun and a grease hammer to push the pins and will create a puller for the front with a HT bolt through a penny washer and socket. If those dont loosen it I will cut the ram eye off and and add manual persuasion to the pin by twisting it while under pressure and adding more penetrating oil to the forward part of the pin. And if that fails there is always my chainsaw Wish me luck. Better yet, wish me patience. Those pins will come out!

Good luck, can you take some pics / video when you do it?

 

[BruceK]

You know I dont have any editing software and the expletives and whingeing will likely get me banned? I shall endeavor to control my emotions but no promises. It's going to be difficult I am under no illusions but I shall persevere.