ACE O.5cc DIESEL RESTORATION

Another patient sent to our E.R. for some resuscitation from our good Canadian friend Adrian Duncan. Here's how he arrived .

Here we have him all dismantled and ready for inspection to determine the extent of his injuries.

The first step in this little man's resurrection is to clean and check the crankcase and crank assembly to ensure all is well with the foundations. Here's the cleaned up parts back together and all playing nicely with each other with the only thing it needed was a small adjustment to the crank/spinner nut fitment to allow the proper tightening of a prop when it comes to test run time.

Next up is clean up the back plate and manufacture the required tooling for carrying out the rebore operation.

Here's the back plate and cylinder head cleaned and ready to refit to the finished engine, and the cylinder liner assembly ready for final lapping.

 

Now to make and fit the replacement piston and contra.

And all final machined and fitted to the restored cylinder assembly.

Next is the reassembly process of the cylinder assembly to the crankcase assembly. Hopefully they'll play nicely together.

So far so good.

Now comes the slightly more tricky bit, making a new tank assembly.

OK so here are the tank and N.V.A. parts that came with this engine from Adrian.

After a closer inspection of these parts, here is what we can reuse, also note that the tank top is missing, the fuel tube and the needle are both bent.

The needle has been bent out of true and here is the reason.

It is plain to see the reason for the needles distortion from correct by looking at the seating jet hole which is miles out of center. Forcing the needle to seat in this position is what has caused it to bend out of alignment and made it unusuable for the new parts we will be making which will of course be properly centered and true.

here's a close up of the needle.

OK so the first step is to make a new tank top to suit the new tank bowl that Adrian has been good enough to provide us.

Now it's onto the new fuel jet etc.

OK so that was a bit of a trial, but mission accomplished, new tank assembly is finished and now we can go get some fuel and turn it into smoke and noise, our favorite passtime.

First pop test run.

Hot restart after refilling the tank, always a good sign.