Well this job was sent in by a friend of mine to see if it was possible to make it run again.......... So to say "that's going to be a bit of a task" is somewhat of an understatement, LOL lets see what we can do.

First job is clean and then remove the seized in old bearings.

So we have managed to remove the bearings from the case without incurring any further damage thankfully. The bearings are actually rusted solid!!!

Next step is to properly clean and refinish the case, clean up the back plate thread and polish the venturi back to like new and replace the "o" ring seal at the same time. Once this is done we'll make a back plate and crank, along with the prop driver and spinner nut.

Here's the cleaned up crankcase ready to proceed with the rebuild.

Next it's onto the venturi.


Well that was the easy part, now we'll start on a full set of tooling to allow us to manufacture all the missing parts etc.

First up was to make and fit the needle jet assembly, then we'll make the actual needle.

after we've done the needle it's onto the crank and front end assembly.

Here's the first stage of the crankshaft manufacturing.

And now ported and ready to fit.

And here's the crank final assembled to the case.

 Prop driver and spinner nut all finished...

Now to get the needle done.

 Her's the needle all finished and also the con-rod and gudgeon pin, ready for assembly once the piston liner assembly is finished.

Here's the con-rod, gudgeon finished and pin and piston, contra piston blanks

ready for fitting.

Next up is the back plate.


And fitted .......


Now it's onto the liner and cylinder head.

Cylinder head first stage, machining the inside.


cylinder head second stage, machining the outside profile.

last stage is to machine in the fins and polish.


Here's the finished head. Now we'll make the compression screw and make a start on the cylinder liner.


Now it's onto the cylinder liner.

First stage of the cylinder manufacturing.

Now it's onto the porting, deburr, hone and lap.


Next up is the contra piston and piston..........


O.K. Lets go assemble this engine........


Righto then where's the fuel bottle........................


We'll give it a good run in then give it a speed test and see what we get.