ENYA 15D REPAIR

This engine was sent in from a friend of mine to see if it could be salvaged to a running engine. It also came with a second very sorry looking crankcase.

First step, as usual, dismantle the engines entirely, removing the old bearings.

The plan was made to restore 1 of these engines and to build a twin ball raced version using the second engine and hopefully we'll be able to bring both of them back to life.

The very keen eyed of you may have noticed something very amiss with one of these cases............

Oh dear, now what?

luckily we have a special process for removing these types of offending broken off bolts/studs etc.

 So having removed the broken section of cylinder head bolt we moved on to refinishing the case and remachining the crankshaft bush out to 12mm diameter to allow us to make a stronger 12mm shaft and replace the odd sized cank bearing with a standard 12x24x6 ball race. This will also allow us to gain an extra 1mm in flywheel thickness and so remove the original flaw these engines had of breaking cranks just behind the bearing.

We had a quick rumage through our parts bins and managed to find 1 original back plate so here it is all cleaned up and ready to fit.

Now we can move onto making the new crankshaft and front end.

 

Next step is to machine in the big end and the ports, final polish and then it's all ready to fit.

In the meantime we've gone ahead and made the new prop driver and washer etc.

 And here's the crank all finished....

All assembled up.

Next up is the new con-rod.

 All assembled and waiting for the cylinder assembly to be done

In the meantime, here's the needle valve assembly all done and fitted. 

Now for the cylinder liner.

Relapped cylinder liner all ready for the new piston and contra to be made and fitted.

 

Piston and contra piston blanks, along with the new gudgeon pin.

Here we have the new piston and contra piston and gudgeon pin all made, fitted and assembled.

 

Now we'll make a new gasket and final assemble the cylinder to the rest of the engine and move onto refinishing the original cylinder head.

Time to mix some fuel up, yay.......

 

And the restart run.............