BMP 3.5cc DIESEL REBUILD NO.2

Here's the patient as he arrived in our E.R.

Adrian told us that there was an issue with the original screwed in big end journal and there might be some other unknown internal problems that will need sorting out.

O.K. mate no problem let's get him all pulled down for inspection and see what's needed shall we.

Here we have him all dismantled and inspected, OH dear what a mess.

Well, needs a new crankshaft and big end pin made, along with a new con rod and despite the apparent feeling of good compression, closer inspection has found that a very poor;y fitting gudgeon pin has ruined the bore and the oval piston hole is further proof of something very wrong in this area. So a rebore will be carried out to return this classic English old timer back to his former glory.

OK, so we'll carry on with the clean and reassemble of the engine in preparation of reassembly after the new shaft and pin have been finished.

In the meantime, we've made a replacement corod.

Here's the new crankshaft blank all ready for final machining and the fitting of the screw in big end journal.

Next step is to machine in the big end pin hole and thread, then counter balance and we're all ready to refit it to the rest of the engine.

And here's the new crank all finished and ready to install back into the engine.

And refitted into the cleaned crankcase along with new bearings.

Now we'll make the new big end journal.

Next up is the piston and contra piston blanks.

here's the new piston and contra piston blanks all ready for set up and final machining to size ready for fitting to the restored cylinder liner.

 

Here's the restored cylinder liner all lapped clean and true along with the new piston,rod and contra piston all ready for final assembly.

 

And fitted to the new crankshaft, and wha'ts more, all playing nicely together, YAY!

Now we'll clean up the tank assembly etc.

Progress so far.......

Now it's just the venturi assembly to finish off, including replacing the old choke pad with a nice new leather one.

Finally here he is all reassembled and ready to breath fire again.

OK so where'd that fuel go?

FOUND IT, OK LET'S GO MAKE SOME NOISE..............

First pop test run.

Restart test run.