Engine rebuild with no former experience........

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10 Dec 2020 21:43 #264465 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Hi Martin, that is interesting, surprising that the crimp onto the barb has not been tightened. Seems risky but obviously works.

My hose is marked Cohnen 370, and is ribbed, it looks different to yours. How did you establish the modern equivalent. I wonder if the size is the same for the 450 and 560?

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I will also try to repair the oil cooler hoses.
Cheers
Jim

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10 Dec 2020 21:50 #264466 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Today I had a closer look at the wear on the rear crankshaft journal.

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Comparison of the old and new seal.

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New seal inserted flush to the surface of the housing.

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From the rear you can see it sits well away from the worn groove.

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Next, more sorting.

Parts to be cleaned or cleaned and painted.

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Parts to be cleaned then zinc plated and yellow passivated.

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I think this lot will take me a few weeks to complete, so no updates for a while.
Cheers
Jim

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14 Dec 2020 22:24 #264733 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
A few cleaned parts, cleaned with degreaser then a Dremel and metal polish....

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...a few more.

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The external head bolts were a bit corroded.

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Cleaned up on a wire wheel.

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]

Re-blued with "Birchwood Casey".

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After sitting in oil for 12 hours.

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The first batch of parts to be plated were cleaned up, this took most of today as they had so much caked on grease and dirt.

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Rust removal.

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These are the bolts that will be saved and re-plated, sitting in brake cleaner.

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Cheers
Jim

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14 Dec 2020 22:24 #264734 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Last, does anyone know if these plastic bushes can be removed or are they over-moulded?

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Cheers
Jim

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15 Dec 2020 21:05 - 15 Dec 2020 21:09 #264799 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
The parts rinsed and cleaned with a scotch bright pad. A few parts will need a second dip in the acid as I think I put too many parts in at once. Some were sandwiched to close together, however most are good.

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The plating works best on polished parts so I used the wire brush on the first part, this should plate nicely. You can still see where the rust had pitted the surface but I can live with that.

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Cheers
Jim

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Last edit: 15 Dec 2020 21:09 by Racediagnostics.
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16 Dec 2020 18:27 #264858 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
The nuts and bolts arrived from Belmetric. Nice!

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Finished polishing the parts from yesterday.

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Then polished the fuel pipes.

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Cheers
Jim

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17 Dec 2020 09:57 - 17 Dec 2020 09:58 #264910 by messerfloh
Replied by messerfloh on topic Engine rebuild with no former experience........
Hi Jim, to clean the valves I used a brass bristle wheel on the angle grinder and a lathe with slow turns to get off the grime. Works fine.
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Scheene Griaß
da Floh


450SLC ´75 Silbergrün
Last edit: 17 Dec 2020 09:58 by messerfloh.
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17 Dec 2020 21:16 - 17 Dec 2020 21:17 #264964 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Today I tried to remove the pulley from the PS pump, however the puller kept slipping off, the manual suggests using a "special tool". So I put it to one side.

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I then moved on to the remaining nuts, bolts and brackets etc.

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More citric acid.

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Back to the PS pump, I tried an alternative approach, I held the pully in one hand and loosened the nut but kept it in place, then hit then end of the tapered shaft with a heavy copper hammer, after 4 increasingly heavy hits it freed off!

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Back to the fasteners, after the citric acid and wire wheel.

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Cheers
Jim

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Last edit: 17 Dec 2020 21:17 by Racediagnostics.
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18 Dec 2020 16:58 - 18 Dec 2020 16:59 #264994 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I picked up a few more parts from the vapour blaster as well as the ceramic coated exhaust manifolds.

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Then removed the ends of the fuel hoses, fortunately they had not been crimped.

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These parts will be too large for me to plate, so will have to find a good plater locally.

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Cheers
Jim

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Last edit: 18 Dec 2020 16:59 by Racediagnostics.
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19 Dec 2020 20:51 #265037 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Today I removed a few more parts from the engine bay.

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The power steering pipes.

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Heat shields.

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I hope this will be the last batch for citric acid.

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There are a surprising number of pipes and tubes that will need to be plated, these will all be too long for me to do at home, so I will get quotes from professional platers. If it is too expensive, I will plate the ends and then paint the main parts of the pipes.

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Does anyone know what is hidden in the rubber sheathed part of this hose?

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Cheers
Jim

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20 Dec 2020 21:09 #265075 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I filed down the welded part of the inlet manifold today with the dreadnought file.

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Then painted the fuel distributer. High Five (four).

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Cheers
Jim

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22 Dec 2020 17:05 #265160 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
I hope this is the final batch of cleaning and citric acid!

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I am in two minds about what to do with the oil filter cannister. It is a bit of a mess but it would be a shame to loose the legend if I were to get it vapour blasted.

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Cheers
Jim

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22 Dec 2020 20:17 #265170 by Thomas2509
Replied by Thomas2509 on topic Engine rebuild with no former experience........
perfect work, Jim.
How long do you put the parts in the citric acid bath?
Let the oil filter canister like it is. It will look pretty good when there is a original part with "patina".

Greetings Thomas
Es grüßt herzlich
Thomas

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22 Dec 2020 20:52 #265171 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Hi Thomas, as these parts were only lightly corroded, they were complete in about 2 hours, however citric acid is not a miracle rust remover. A lot of effort is required, degreasing before the acid, then afterwards, individual "rinse and scrub", then heating of the component to stop flash rust appearing, and final finishing using a wire wheel.

Some types of steel come out of the acid fairly clean and others come out with a black coating that has to be removed with detergent and an abrasive scotch pad.
Cheers
Jim

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23 Dec 2020 23:17 #265209 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
Hi Jim,

how do you heat the components? To a certain temperature or intuitively?

Regards,
Lutz
Alle Lebewesen außer den Menschen wissen, daß der Hauptzweck des Lebens darin besteht, es zu genießen.
Samuel Butler

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24 Dec 2020 00:50 #265212 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
It's very low tech, just a quick blow dry with a hot air gun till all the moisture has evaporated. It takes 10 or 20 seconds per item depending on its size.
Cheers
Jim

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27 Dec 2020 17:44 #265302 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Today I got back to the project, set up the plating room again.

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These are all the parts I cleaned, most need plated except the top row.

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I noticed this on the thermostat cover, do you think it is a poor casting or corrosion? Either way I'll look out for a replacement.

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Cheers
Jim

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07 Jan 2021 19:14 - 07 Jan 2021 19:44 #265880 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
While getting on with the plating I did a bit of clean up on the warm up regulator and the distributor vacuum pod.

The pod is a bit rusty but is functional and a replacement is more than £100, I couldn't dip in acid to clean off the rust and zinc for plating as it's not watertight.

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Instead I sanded it down and painted it.

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Then on to the WUR, just circular port area that was a bit rusty.

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Painted with newly plated ports.

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I hope that the plating will finally be completed tomorrow.
Cheers
Jim

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Last edit: 07 Jan 2021 19:44 by Racediagnostics.
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07 Jan 2021 21:58 #265901 by Dr-DJet
Replied by Dr-DJet on topic Engine rebuild with no former experience........
Hi Jim,

well doen on ignition distributor. On WUR port area is actually raw. So I only polish t and use some transparent paint on it. But you have to keep ports and ring area around it clean to ensure that copper rings can seal afterwards. I also made some brass replacement for the adapters on top so that they will never rust again.
Viele Schraubergrüße - best regards, Volker, Admin und Betreiber dieser Webseite
Fast alles zu Zündung und Jetronic auf jetronic.org

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08 Jan 2021 11:35 - 08 Jan 2021 11:38 #265933 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Finally the plating is finished. It's probably not much cheaper (and it is a lot of work) to do it yourself but you don't have to worry about parts going missing at the platers.

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And on top of that there is the 400+ new nuts and bolts.

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Cheers
Jim

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Last edit: 08 Jan 2021 11:38 by Racediagnostics.
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08 Jan 2021 11:49 #265934 by T-Modell
Replied by T-Modell on topic Engine rebuild with no former experience........
Hi Jim,
that's a great result of your galvanising ... so you did it yourself? Took the brush, the gold colour of your kid's watercolour box and started? ;-)

Regards and good luck with the rest of your work
Thomas

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08 Jan 2021 17:41 #265969 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Hi Thomas, yes, it took about six days of work, gold spray paint would have been much quicker.
Cheers
Jim

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08 Jan 2021 18:14 #265974 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
Hi Jim,

how did you do it? Or did you write about this before? I don't remember .....

Regards,
Lutz
Alle Lebewesen außer den Menschen wissen, daß der Hauptzweck des Lebens darin besteht, es zu genießen.
Samuel Butler

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08 Jan 2021 18:24 #265975 by Seewolf107
Replied by Seewolf107 on topic Engine rebuild with no former experience........
Wow nice job Jim !

I did a lot of parts myself too.....it is extremly time consuming and the setup is not cheap.
Grüsse Claus
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08 Jan 2021 20:26 #265980 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Hi Lutz,

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Four 10l tanks for dipping and four buckets for rinsing. All tanks have 30 degC heaters in and the plating tank also has a circulating pump/filter.

Tank 1 is a caustic cleaning solution to remove grease. Leave parts in here till very clean, then rinse.

Tank 2 is 100g of Sodium Fluoride + 900g of Sodium Hydrogen sulphate for etching. Parts stay in here for 30 seconds prior to plating, then rinse.

Tank 3 is 200g of Zinc Chloride + 1200g of Ammonium Chloride, + 4 zinc electrodes + a bench power supply. Parts stay in here for 45 minutes at ~ 70mA per sq inch.

Tank 4 is 600g of Sodium Dichromate + 25ml of conc sulphuric acid.. Once parts are plated, I rinse them first, dip for 4 seconds in Tank 2, then rinse again, then dip in tank 4 for 4 seconds and then rinse again. The parts are then left for 48 hours for the passivation coat to harden.
Cheers
Jim

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08 Jan 2021 21:53 - 08 Jan 2021 22:00 #265986 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
Hi Jim,

I don't want to bicker but on the bucket for tank 4 you wrote 10 to 50 seconds, not 4 seconds ..... :huh:
And what kind of caustic cleaning solution is this? Caustic soda?

Regards,
Lutz
Alle Lebewesen außer den Menschen wissen, daß der Hauptzweck des Lebens darin besteht, es zu genießen.
Samuel Butler
Last edit: 08 Jan 2021 22:00 by Chromix.

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08 Jan 2021 22:05 - 08 Jan 2021 22:41 #265988 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
Ha ha, I tried two different formulations for the passivation, first I tried a tri valent chromate that I didn't like, then swapped to the hexavalent chromate which had a higher concentration and thus less dip time.
Cheers
Jim

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Last edit: 08 Jan 2021 22:41 by Racediagnostics.
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08 Jan 2021 22:16 #265990 by Chromix
Replied by Chromix on topic Engine rebuild with no former experience........
Thanks, after thinking through the process, the next question came up:
How do you do the plating? Probably not part by part. So many parts in the tank that they don't touch each other? + to the zinc and - to the parts?

Regards,
Lutz
Alle Lebewesen außer den Menschen wissen, daß der Hauptzweck des Lebens darin besteht, es zu genießen.
Samuel Butler

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08 Jan 2021 22:38 #265995 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
The caustic solution is 10l of distilled water with.

SODIUM CARBONATE 250g
SODIUM TRISILICATE 250g
SODIUM HYDROXIDE 400g

Here are a couple of examples. Negative electrode to the parts to be plated, positive electrode to the zinc plates.

Small parts were plated together, larger parts by themselves. The long fuel pipes were plated partially in two session.

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Some parts come out shiny, others dull. The parts that come out dull are lightly rubbed with fine wire wool to bring out the shine before being dipped in the acid, then chromate.
Cheers
Jim

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08 Jan 2021 22:52 #265996 by Racediagnostics
Replied by Racediagnostics on topic Engine rebuild with no former experience........
The sodium dichromate is also useful for adding colour to new hardware.

First a quick dip in the acid pickle, rinse, then dip in the chromate.

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Power steering cooler hoses.

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Cheers
Jim

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Heute möchte ich Euch zeigen, wie man ohne grossen Aufwand die Steuerkette wechseln kann, am...

Racediagnostics - 05 September 2021

Jim did a full restore of his car and of course he did not like his sun visors to be old bumpy...

Dr-DJet - 11 April 2021

im Rahmen der Tacho Recherchen stellte ich fest, dass es nirgendwo richtig oder nur...

Dr-DJet - 18 November 2018

It took till September 1981 that R107 SL received a heating system with pulsed mono or duo valves...

Frank25 - 30 September 2018

Ihr wollt wissen, wie Euer Stoff-, MB-Tex oder Lederpolster von 1979-1981 ausgesehen hat? Frank...

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