Thanks DSPTurtle!

The ultimate reward will be Dad firing up the old rig and taking it for a spin!

Alrighty....

I did not get as much time as I had planned to work on the engine while I was away from the office.

What I was able to do was the following:

Install the new flywheel seal.



http://forums.pelicanparts.com/uploa...1356973356.jpg


Pick up and install the flywheel (new bolts and pilot bearing installed)

http://forums.pelicanparts.com/uploa...1356973417.jpg


I brought some of the other parts to the guy who is doing the sand blasting and powder coating for me.

With the fan and alternator removed, I was able to bring the alternator to a shop to get it tested: all is well there.

Seeing that it will be a couple weeks before I get my parts back (PC guy is very busy) I will be working on a couple other areas of the engine (confirming valve clearance and such). I also am expecting a couple part deliveries before I can start to put things back together.

Now that I have a moment to post up a picture (or three) - these are the last two seals that remain in the gasket and seal kit that came with the motor when I picked it up. They are both ~57-58mm in diameter, and I do not know what they are for (yet). I originally thought that the orange one was a thermostat seal ring - but it is too large in diameter for that. The black one looks like it may be a main bearing seal - but again, I am just taking guesses at this point. Any thoughts of what these seals are for?

http://forums.pelicanparts.com/uploa...1356974395.jpg

Moving on....

I guess that I will figure out what those two seals are for as I continue. Feel free if someone happens to take a glimpse at the thread so far who knows what they are for....

Against my 'better' judgement - I knocked out these "core plugs" of the timing chain covers - thinking that I could buy a couple somewhere. After a frustrating number of phone calls and inter-web searches - it appears that these are not made by anyone, nor carried by anyone, never were, and are made of "unobtainium".

They are 15mm in diameter, and about 4mm in depth. They go in the timing chain cover, and our host does not carry the plug as a separate item. The material is colored steel even though they look bronze.

I encountered a similar issue when I was working on the vette engine years ago, I ended up buying a bunch of various sizes from an engine builder. That builder is no longer in business.

Where can I get some of these????

http://forums.pelicanparts.com/uploa...1357412654.jpg

Why did you knock it out? Just reinstall if you didn't deform it, maybe use a little 574.

Items in question in post #22, just a WAG, would be nose bearing o-ring and seal. O-ring requires splitting the case to replace. Seal can be replaced with bottom end assembled.

Thanks dtw: I apreciate the input.

So - I knocked these core plugs out of the timing chain covers because I was thinking that when I the housing covers back from the PC shop, I would install a new core plug (post PC) - insuring that there would not be another potential oil leak spot... thinking that a new one would be better than the old one there, post PC, as the two different materials would not agree well during the heating/baking phase of the PC process.

Now after having looked at fellow pelicans who have coated their chain box covers, I realize that I could have been able to get away with leaving them there, and the PC would just cover the brass color ...no big deal.

I did not deform them too much, so - if I cannot get a couple replacements, I will have to re-use them. I *have* to imagine that these core plugs are available somewhere!

These core plugs have to be available somewhere... anyone know where to get a 15mm core plug?

Well - since I was unable to locate a shop - ANY WHERE (globally) - that could get me a pair of replacement 15mm core plugs - I decided with the route that I was afraid of to begin with: re-use.

Here are some pics for those curious: it doesn't look *bad* - but I would have liked to install a new pair.

pre-installation:
http://forums.pelicanparts.com/uploa...1357840788.jpg

The sealing material that I used:
http://forums.pelicanparts.com/uploa...1357840840.jpg


And then; finally one of them installed:
http://forums.pelicanparts.com/uploa...1357840877.jpg

I am really quite shocked that this is not a part that is able to be purchased - even though it is used in the timing chain covers for the Carrera upgrade.

I verified the valve-to-piston clearances, set the rocker to valve clearance; and I think that it is time to move on to the next parts of assembly.

We will move on to installation of the alternator, timing chain covers, and other components that I got back from the PC shop. I will take pictures and post as I make some progress.

Aren't those the plugs that you simply smear JB Weld over (on the inside) to seal anyway? Did they have some hard gray stuff over them (inside) when you popped them out?

Very nice work . . . and photos
Keep up the good work!!

Regards,

GaryR

When I removed those two plugs, they were not covered in JBweld (in fact, they looked dry). I suppose that I could add some, but I do not believe that these plugs refered to in the 101 book that you are to 'smear' some JBweld across on the back. I believe that those were in the more "oil populated" areas of the engine that have a plug.

Lesson learned here to me: do not remove pieces parts like this in a restoration until a replacement part has been located and/or purchased.

Timing chain cover installed
 

I have to say that I must work at a snail's pace when compared to others on the forum.

I picked up where I left off (a couple weeks ago) last night, and only had a couple hours to work - as things have been busy for me. Anyhow, I was able to install the timing chain cover gaskets, covers and SOME of the oil lines for the tensioner. I have to get some new "seals" from the nuts and bolts store nearby (not just a HW store) to finish the oil lines install.

http://forums.pelicanparts.com/uploa...1359648254.jpg

Slow... but steady progress...

What is the purpose of the rusted black painted engine tin that goes across the barrels?


http://forums.pelicanparts.com/uploa...1354897285.jpg[/QUOTE]

BTW - where are you in the motor city area?

motogman:

That piece that you're referring to is a stamping that holds the metal air shields in place that guide the air in between the cylinders.

These parts were sandblasted, PC'ed and re-installed - look "good as new" now.

Motor city: I am a little north - in Clarkston.

Thanks. I have to go look at the parts diagrams... Were these shields used on all motors? They are my 3.2L I am working on.

I am on the other side of the Motory City Planet - SW a ways. Otherwise it would be cool to check out your project.

I believe that these air baffles are used on all of the air cooled engines, but I am a newbie by measures on this forum.

I was able to get a little more done on Saturday...


http://forums.pelicanparts.com/uploa...1360001702.jpg

Next steps: I am going to try to find someone locally who will help repair the exhaust manifolds. There is one that needs some welding done, and I can't weld.
Hopefully it can be salvaged - and then they will be installed.

Nice work - looks great.

Heat exchangers installed last night, just after I ensured that the front engine bar was "level"

To say that the nuts and washers (on the heat exchangers) must be installed by one with a contortionist's hand is understated.

Today I will be making a purchase to get the exhaust "cross over" pipe hardware and gasket set.

I am going to fight with the alternator/fan assembly today at lunch to get the fan on there correctly and give a go at installation this evening.

http://forums.pelicanparts.com/uploa...1361897656.jpg

Fantastic!

I was able to get the fan back together with the alternator and fan housing. I am not going to bore y'all with the picture of the alternator/fan assy until it is installed.

Looking ahead:

CIS system
I have a little work to do on the CIS system, which I estimate to be about 3-4 hours - or - 30 minutes to the trained pelican-er. Question:

(1) What do I have to do to test the injectors? The system seemed to work just fine when the engine was dropped years back, but I am a little apprehensive that things are still OK with it having sit for as long as it has.

(2) What other items need to be checked out while in the CIS system? I am already in for an airbox, it is trashed.


Clutch system

Is it possible to just replace the friction disk on the clutch sub assy? I am not nuts about replacing things that don't need to be replaced, and the other items seem OK.

You can make up a jig to test them for flow but if I were you I would send them out to be cleaned, flow/spray pattern tested, and balanced by someone like Marren Injectors. You get them back, toss them in with new seals, done.