ETA "5"R RESTORATION

 

This rather sad looking ETA "5" R was sent in to us by my good friend Adrian Duncan with the request to "please make it like new again" And do whatever mods you deem necessary.

Sure mate no problem. Here's the engine as we received it from Adrian.

 

First step as always is to completely dismantle the engine and assess it for the required work and then make a plan on how to carry out said mission.

 

Well, now that we've managed to get it all apart without too much trouble we can see what needs to be sorted. The initial request from Adrian was to fix a worn out crank and main bush, along with a flogged out conrod. We checked the compression before dismantling and while it wasn't really poor, it wasn't that flash either so rebore and new piston, contra, gudgeon while we're at it. We will also correct the "A typical English" method of "the most complicated, time consuming and difficult to maintain" design by replacing the screwed in and stake so it never comes apart, ever, con-rod carrier for the more conventional pressed in gudgeon and a fairly well lightened piston at the same time.

Well, lets get on with the show then.................

 Here's the new conrod machined up from billet.

Next up its process the crankcase and machine up a new crankshaft.

Here's the nicely refinished case.

Now it's onto the crankshaft and front end.

 Here's the new crankshaft blank all ready to machine in the big end etc.

 Crankshaft all finished and counter balanced to boot...

Next up is to make the new front end and reassemble progress so far....

New con rod fitted up and the original back plate cleaned and refitted with a new gasket.

Progress so far with the new spinner nut as well...........

Next up is relapping the cylinder liner and machining up the replacement piston and contra piston.

Here we have the cylinder studs nicely cleaned up and refitted to the case.

Now we'll move onto restoring the cylinder liner and machining up the new piston and contra.

 Relapped cylinder refitted to the cylinder casting and ready for the new piston and contra.

 Here is the new piston and contra piston all made and fitted up to the relapped liner and ready for final assembly.

Next up is the strip down and polish of the original cylinder head ready for reanodizing along with the new spinner nut.

 

And here he is all sparkling and refreshed. Another fine old distinguished Englishman saved from the brink of the rubbish bin to live again.

Now lets bring him to life...............

First pop test run.

Hot restart test run.