Musky's Plunger rebuild.

[muskrat]

G'day Fellas
Trevor, I rang JP and the only ones they can supply are 6.6:1. Way to low for my alloy head, 357 cam, 932 carb
So GB expect a PM. Those pistons look very similar to my old 8:1's.
Cheers

[muskrat]

G'day fellas.
Greybeard has bought the pistons for me. Now the 3-4 week wait for them to swim halfway around the word.
With the SRM oil pump and the inner timing cover on I primed the crankcase with a cup of oil. I attached a tube to the feed pipe and filled it with oil. Turning the motor over by hand showed the pump was taking oil. Probably another 30-40 turns had oil coming out the return pipe. Holding the rods up and turning the crank by hand was slow. I joined the feed and return pipes with he tube. Placed condoms on the rods and was now able to use the kick lever to spin her over a lot quicker. Oil kept flowing round and round.
I haven't drilled the case for a oil pressure gauge or bought an SRM OPRV yet so will do before the pistons arrive.
Cheers

[Greybeard]

You might consider using a couple of elastic bungies to keep the conrods upright.

I hope you are going to wash those condominiums before you use them again.

[muskrat]

You might consider using a couple of elastic bungies to keep the conrods upright.

I hope you are going to wash those condominiums before you use them again.

G'day GB.
I tried elastic bands and bungie cords to no avail.
Mate, condoms are a one use only. I hate the smell of burning rubber in the morning 
Cheers

[muskrat]

G'day Fellas.
Wild cold wet windy out so gave her a head job Just a quick wash and decoke then a light grind of the valves & seats. Didn't really need the grind but wanted to check the guides. All good and back together. Also gave the rockerbox a wash.
The barrels got a clean and fresh coat of gloss heat resistant 2 pack black.
The top end of this motor is from my 57 A7SS racer. Been on since the mid 90's so has a few  bits 
Cheers

[muskrat]

G'day Fellas.
The new pistons arrived yesterday so tonight I got a bit done.
The compression height of the new are 3mm shorter. The old ones were 8.5:1, the new look like 7 or 7.5:1. I don't really need to ride her like I stole her any more  . Next the scales came out. The new pistons bare are only 1g heavier but the pins are 10g heavier  The old pins had a straight bore but the new pins bore is tapered (thick in the middle). Too late in the evening (beers) to work out balance factors and how much 10g will alter it. Think I'll go with the old pins. They fit nicely in the new rod little ends with no perceivable play and measure 0.001mm (0.00025") under. 
Then the lathe and dremel got a bit of use. First cut a 30 degree chamfer in the skirts fore and aft and dremel the sides to blend in. This cuts through the oil on the cylinders instead of rolling it down with the flat edge of the skirt. It also aids little end lube and cools the crown of the piston.
Hopefully by the end of the weekend she will be buttoned up.
Cheers

[RDfella]

Crime? Should be a requirement - these days you don't know what's up there ......

[muskrat]

G'day Fellas.
She lives. Started 3rd kick. No horrible noises. You know how it is, all the thoughts of did I tighten that, did I locktight that as you give it the first kick.
Now I'll take her for a lap and bed the rings in, then check the timing.
Will have to go back and fill in the gaps with the story.
Cheers 

[WozzA]

     Well done mate..... I've enjoyed your postings..   

[muskrat]

G'day Fellas.
Continuing on from reply #95.
I used the old pins and heated the pistons with the hot air gun to mount them on the rods. Pushed in nice and easy, burnt my fingers before I used gloves  . Made a piston support out of the trusty nylon cutting board and ring compressors out of poly pipe and hose clamps. Installed two of the through studs to keep the barrels square and slid them down over the pistons. Less chance of breaking a ring that way.
Installed the studs with red loctite. I annealed the head gasket bring it up to red all over the when cooled gave it a good coat of coppercoat.
The head slid down the studs nicely and was torqued down to 20-25-30ftlb.
Next was the job we all love "not" the rocker box. I must have done it hundreds of times but it still took me two goes at it. As I don't use the springs on the rocker shafts (shimmed instead) the rockers flop down so use elastic bands to hold them up. You will notice the extra large cover studs and 4 long box bolts. This top end was from my 57 A7SS racer and all the threads were shot. Quick fix go bigger  . The beauty of it in a plunger means the rocker box isn't stressed by the s/a head steady so rarely leaks. For tappet clearance I gave them 12 and 14 to start.
Then it was time to throw all the ancillary bits on. Probably the most time consuming part of the job. I left the tank off and hooked up my auxiliary tank to see if she lives.
Third kick she bursts into life and ran for a couple of minutes. On with the tank and out on the road. I like to put load on as soon as possible. About 15 minutes around the back streets of Lithgow and back in the shed. Off with the primary to check the timing. Spot on 35 degrees so didn't touch it. Back on with the primary and back out on the road. This time up and down Scenic Hill twice to load her up a bit but not labor her.
All good, no horrible noises and no oil leaks
Cheers

[muskrat]

G'day Fellas.
This morning when she was cold (1C in the shed) I checked the tappets. They had closed up a tad so reset at my preferred gaps. 10 & 14 is 2 thou bigger than in the book but I don't ride like the book
Started 2nd kick and sounds great (no baffles) through 40 year old stainless pipes.
I won't ride now till the new carb arrives.
Cheers.

[Colsbeeza]

Geez that's a beast Musky.

[Greybeard]

That all looks great 👌 Well done; it almost looks like you've done it before 👍

[RDfella]

There used to be a varnish-like substance (Wellseal if I recall correctly - came in a small bottle) that one could paint onto gaskets. Often used on head gaskets. Dunno if it's still obtainable. Have some somewhere but never think to use it.

[Greybeard]

Musky's balls are so huge that his engine may blow a gasket of he doesn't put jollop on. I just anneal mine, (the gasket that is).