Well Guys and Girls, I once again got a bit done on the old iron. Having checked the run out in the new crankshaft I am convinced that the new bushes are a fraction too tight. I have scrapped the bushes a touch and everything now turns freely. Perhaps a little tighter than I would like, so I intend to hook it up to an electric motor and run it in on the bench, a couple of hours with an oil change after should flush out any crap and ensure good longevity.
Sadly the keyways on the new crankshaft are about a half inch shorter than the original. This has made it impossible to refit the oil thrower rings as per the original. I have had to file off the lugs that located into the keyways and then set them with medium strength Loctite.
Flywheels have now been fitted, with an anti seize compound. Because the keyways are shorter I have had to shorten the gib keys and file a radius on the leading edges.
So now I need to address the issues with the camshaft and idler gear. The idler gear itself looks to be OK but does not mesh well with the pinion on the crankshaft. I will be turning up a new spigot with an offset as per 38ac`s instructions on the WOK. I need to know how to guesstimate the correct offset.
The camshaft is badly worn at the oil pump/injector end (lubrication issues) however the other end that runs in a steel bush is serviceable. I dry assembled that end of the shaft (see photo) and found 20 thou of end float in the old bush. I ordered a new bush, when it arrived it was of such poor quality that I wouldn`t dream of fitting it. It is also 25 thou shorter than the original, worn, item and takes the end float out to 45 thou. I am guessing that the correct end float is between 5 and 10 thou as per the crankshaft. Dieselspanner did a fine job of making new bushes, so I intend to follow his advice. I have a piece of 1.25" diameter cast iron for one end and an undersized oilite bush for the other end. I will turn down the worn end of the camshaft and then turn the Oilite bush to fit.
I am guessing that the important issue when doing this work is to ensure that the cam gear aligns well with the idler gear and then dimension the new steel bush to keep it aligned, clearly too much end float in the camshaft will also impact on the accuracy of the governor assembly and how accurately the engine maintains RPM under load. Advice please.
I also ordered a new cast iron cover for the non injector end of the camshaft. The new cover looked fine on the outside but was full of casting sand inside. It has now been cleaned and painted inside and out.
Info on end float please,
Bob