KEILKRAFT K6 RESTORATION

Here is the engine as we received it from Adrian.

Let's get it dismantled and assessed for repairs.

Oh Boy, what looked like a not so bad engine on the outside had some hidden rottenness that will need to be removed in order to bring this old English gentleman back to a state of good health and running order.

 

Apart from a good clean the main issue that needs resolving is the obvious broken piston and a seriously flogged out rod and gudgeon pin, which has left the liner not to bad but definitely needing some love.

First step is to clean everything up and prepare the good parts to be reassembled once the replacement parts have been manufactured.

OK so having cleaned and measured all the other main parts we've found further issues.

Unfortunately the crankshaft is badly worn on both the main journal and the big end which has a 0.1 taper towards the back of the engine worn into it so the rod is going to always want to rub against the rear face of the case if this is left untreated.

Sooo a new crankshaft will now have to be manufactured and so we will take the opportunity to make it as a 1 piece unit with slightly altered flywheel layout.

We decided to start with dismantling the original piston assembly and manufacturing a new con rod and piston.

Here's the new piston blank all ready for final machining to size. We have replaced the riveted together multi piece setup in favour of the much more user friendly pressed in con rod set up.

 

All our replacement conrods feature lube hole in both the top and bottom bearing to ensure good lubrication and long life.

Here is the cylinder liner all cleaned and rebored ,lapped and ready for the new piston assembly to be final fitted and reassembled onto the rest of the engine.

Now it's onto final machining the new piston to size and fitting it up to the reconditioned cylinder liner.

Out with the old and in with the nice new piston/rod assembly.

Ready to go back on to the rest of the engine.

Now we'll carry on with the new crankshaft and reassemble the engine for test running.