TAIPAN MK8 SERIES 65 2.5cc DIESEL

My good friend Callum Henderson sent us in another Taipan diesel looking for a new lease on life. Well our E.R. is a little bit swamped at the moment mate but let's see what we can do.

Here's the engine as it arrived on our doorstep.

 

O.K, so lets dismantle him and see what needs to be done to bring him back to life.

Well, not toooo bad, case needs a bit of a tidy up and a new crank bush, the crankshaft itself is actually badly worn on both the main bearing and the big end journal so I think we will be making a new shaft. He also needs to have some compression added back into him and the rod is slightly worn out, N.V.A. and some cosmetic adjustments. So, well not to much then, LOL.

Here we have the case all cleaned and refinished, main bearing has been resized to take the slightly larger new crankshaft. Back plate has also been given a new lease on life and the cylinder head as well.

Next up is to finish the new crankshaft and front end.

Here's the crankshaft blank stage 1 with the big end machined in.

 

And the finished crankshaft.

Refitted to the case with the front end.

Here's the replacement N.V.A. and conrod all fitted up and ready for the piston /liner assembly to go on.

Next up is to make the tooling required to relap the cylinder liner and to manufacture the piston and contra piston blanks ready for final machining to fit the refinished cylinder liner.

Here's the re-lapped cylinder liner with the new contra piston made and fitted.

Now we'll make the new piston and gudgeon pin, then reassemble the engine for test running.

Piston blank finished and ready for final machining to size, lapping to fit the cylinder. New gudgeon pin also ready.

All the parts made and fitted and ready for final assembly.

Now its time to oil and assemble the engine and finally we can add some fuel.

Now where's that fuel bottle gone?