TAIPAN TYRO 1.9cc DIESEL RESTORATION

Well we received this crankcase from Mr Henderson with the enquiry as to whether or not we could restore this engine to running like new condition?

 

LOL...................... Well yes but ummm thats a bit of work right there mate.

OH and by the way, there's a broken off cylinder bolt stuck in it too....................

Great, another mission impossible.

OK so we'll start with the removal of the broken bolt and go from there.

Here's the crankcase with the broken off bolt removed and having received our case restoration process, new 4/40 bolts have been fitted into the case to avoid losing them, lol.

Here's the crankshaft bush removed and ready for the new part to be made and fitted.

Here's the new crank shaft bush made and fitted, inlet hole re drilled and the new prop washer and nut.

now we'll sort the N.V.A. and a new back plate.

Back plate made and test fitted.

Here's the progress so far on this rather involved restoration mission.

Now it's onto the crankshaft and prop driver.

Crankshaft blank, step 1.

Next........

Now that the crankshaft is completed we can reassemble the bottom end with prop driver etc.

Now we can make the cylinder head.

Now it's onto making the cylinder liner and the piston/rod assembly.

Here we have the new con rod and gudgeon along with the new piston and contra piston blanks.

Progress to date.

Next step is to machine up an new cylinder liner.

Here's the first step in making the nw cylinder liner for this engine.

And parted off ready for the next stage, machining in the exhaust port and bolt holes.

Now it's off to the mill we go.

First mill op done, next up is the transfers and boost port.

Here we have the liner all trimmed up and ready for the 2 transfer and boost port to be machined in.

Yes there's only 1 exhaust port, because we are making this a schnuerle ported engine just for fun.

Here's the new cylinder all machined up and ready for deburring and polishing before we start the hone and lap process.

And here we have the piston and cylinder liner assembly completed and ready to fit to the rest of the engine.

Assembly of the engine.

Here we have the engine fully assembled and looking for his first feed of fuel.

First pop run on a 9 x 4 prop for easy smooth first run.

We'll give him a few runs then start testing on some smaller props.

Hot restart test.