Winter 44 Builds

Show & Tell time! Photos, comments, stories, etc

Winter 44 Builds

Postby ctpdsr » Sun Nov 05, 2017 11:41 pm

Hi Guys.

The shop is filling up with Winter projects. A good thing. Rather than document another start-to-finish build, I will update this spot from time to time with (I hope) interesting bits I find along the way. The list so far includes finishing the FGS short shaft 44 for my brother Jim’s GW Invader project, a tune up for my son Nick’s Sport Port 44 after 10 years of service, and a very special D-Mod 40 that has multiple National Championships under it’s belt. That’s the block on my staging table next to the Arbor Press. Time to order some parts!

Chuck
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Re: Winter 44 Builds

Postby Deep C » Mon Nov 06, 2017 1:28 am

Chuck hope you save some time for some carbs and a mag tower, will have to get them there but I have a boat to paint too.
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Re: Winter 44 Builds

Postby Tom Brockmeyer » Mon Nov 06, 2017 3:12 pm

...and I hope Chuck saves time for a 30H refresh and a to go thru a newly aquired 1987 Merc "Classic50" powerhead for my 44XS lakeracer build!
I'm trying to figure out a time to road trip to Chuck's "Shop/Museum" and finally meet him in person.  Might be able to meet SteveC along the way.

Tom
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Re: Winter 44 Builds

Postby Fastjeff » Mon Nov 06, 2017 3:55 pm

His shop makes mine look like a ghetto crack house.

Jeff
Words spoken in two stroke heaven: There's no fuel like an oiled fuel.
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Re: Winter 44 Builds

Postby Deep C » Thu Nov 09, 2017 3:36 pm

It is stunning I will say that and the finished product is just as stunning.
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Re: Winter 44 Builds

Postby ctpdsr » Sat Nov 18, 2017 11:08 pm

A few notes from the shop today.

These two powerheads are essentially identical in terms of internal parts. The Merc500 block on the stand was built 15 years ago and is the motor you saw running on my son Nick's GW Invader in the calendar photo. I have no reason to tear down further at this point. It runs like a champ, but could benefit from a carb, mag & fuel pump rebuild. I also thought a lighter flywheel might not be a bad idea.

I did not have the inventory in 2002 that I have today. I like using service flywheels with the solid cast dogs on all my motors. Some are bare. Some have ring gears. This one had both a ring gear and magnet. We used to cut down these service flywheels for racing. Both large taper and small taper crank versions exist, but the large taper (newer) guys are harder to find. Same with 55H factory jobs. I found a nice candidate on the shelf. I like using service flywheels for these sport non-shift engines, but keep the stock diameter for idling purposes.

A recent post asked if Merc400 vs. Merc500 carbs made a big difference. The Merc 400 powerhead on the bench to the left has model KA9 carbs. The early Merc 500's had KA13 then KA18 carbs with the same venturi length. Newer KA19 models went to a shorter length. All work well and you would be hard pressed to tell the difference on a service engine. Remember, a good bit of the hp rating difference came from the tuned exhaust snorkel in the 500 rated at 50hp vs, the 400 rated at 45hp. But I digress.

Note the slightly longer 5/16" fine thread crankcase  bolts with the small hole used to affix the lead factory seal cable are just the right length for use with a flywheel puller!



Chuck

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Re: Winter 44 Builds

Postby daveswaves » Sat Nov 18, 2017 11:26 pm

Yup, i saved all the nuts and bolts from various mercs and am still finding use for them.  Nice puller.
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Re: Winter 44 Builds

Postby necks » Sun Nov 19, 2017 12:09 am

ctpdsr, How do you find time to keep a shop that clean, and find time to repair and rebuild outboards in the same place,? You must have a good janitor.?
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Re: Winter 44 Builds

Postby Fastjeff » Sun Nov 19, 2017 12:42 pm

Obviously, he doesn't do fiberglass construction and welding/ blacksmithing in his (like I do). Makes a hellova mess!

Jeff
Words spoken in two stroke heaven: There's no fuel like an oiled fuel.
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Re: Winter 44 Builds

Postby zul8tr » Sun Nov 19, 2017 12:52 pm

Love that work area. Mine is multiple use for anything that needs fix'n  :-)
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Re: Winter 44 Builds

Postby Fastjeff » Sun Nov 19, 2017 2:59 pm

..."Mine is multiple use for anything that needs fix'n."

Mine too--unfortunately.  When I win the lottery (Hah!  Yet to buy a ticket) my super shop will have an area dedicated to blacksmith work only, with another for body work only and f-glassing. The mechanical only shop will stay nice and clean that way.

And then I woke up!

Jeff
Words spoken in two stroke heaven: There's no fuel like an oiled fuel.
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Re: Winter 44 Builds

Postby ctpdsr » Mon Nov 20, 2017 5:17 pm

Thanks guys.

I really don't have much space, so everything needs a home. I started out in 1989 with the used office desk that came with a laminated top. Ugly, but it is solid oak and the top can take a beating. I bet I have disassembled well over 200 engines on this old thing. Jerry designed and had the powerhead stands welded up years ago. He uses the same one in his (much larger) shop. The idea to attach a simple but very effective motor stand using a vertical 2x12" plank was also copied from the master. I am getting ready to install all the linkage bits for the 44 FGS project and will share some details soon.

Chuck
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Re: Winter 44 Builds

Postby ctpdsr » Tue Nov 21, 2017 6:58 pm

Setting up the linkage bits prior to dropping the powerhead. Since we are using the newer style mag drive and throttle linkage, I found a nice set of pan levers for this build. I always set everything up in the "Neutral" position and test prior to installing the powerhead. Note the cast line in the shift lever at the very end. My guess is this helps to line up the system in center neutral position using the brass remote control cable mounts. I never noticed this before. A smart guy told me once, "you can learn a lot just by looking..."

Chuck
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Re: Winter 44 Builds

Postby zul8tr » Tue Nov 21, 2017 10:44 pm

ctpdsr wrote:Thanks guys.

I really don't have much space, so everything needs a home. I started out in 1989 with the used office desk that came with a laminated top. Ugly, but it is solid oak and the top can take a beating. I bet I have disassembled well over 200 engines on this old thing. Jerry designed and had the powerhead stands welded up years ago. He uses the same one in his (much larger) shop. The idea to attach a simple but very effective motor stand using a vertical 2x12" plank was also copied from the master. I am getting ready to install all the linkage bits for the 44 FGS project and will share some details soon.

Chuck
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Nice neat work. Those gram weights written on the 4 pistons crowns; do they include the pins, retainers and rings or....... :?:
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Re: Winter 44 Builds

Postby ctpdsr » Wed Nov 22, 2017 12:00 am

Good question Zul. I was told once to always keep the original pistons and pins together as a set, so after clean-up, I weigh the piston and pin as a unit. Spacers are prepped separately paying close attention to the finish and thickness of each.

Chuck
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Re: Winter 44 Builds

Postby outboard315 » Wed Nov 22, 2017 12:10 am

Drool, drool, oooo, ahhh.
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Re: Winter 44 Builds

Postby Deep C » Wed Nov 22, 2017 12:41 am

Drawers full of weighed pistons, it is something to behold.
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Re: Winter 44 Builds

Postby zul8tr » Wed Nov 22, 2017 2:50 pm

ctpdsr wrote:Good question Zul. I was told once to always keep the original pistons and pins together as a set, so after clean-up, I weigh the piston and pin as a unit. Spacers are prepped separately paying close attention to the finish and thickness of each.

Chuck


Chuck

So I assume they are weighed with just piston + pin  :?:  Are those std. bore pistons  :?: If over bore what amount ?
On the spacers do you mic the total width with 2 spacers on the rod  :?:
Do you check the opening in the pistons that the rod and washers go so clearance can be calculated :?:  What clearance do you shoot for  :?:  

With SS reeds I gram weigh them and select the closest in thickness (I use .012" in the 25ss), do you do that :?:  

I showed the pics of your   8-)  neat shop to my wife, she is motivated to help me with my shop in a corner of the garage  :-) It is always a chore to do with 2 cars, lawn equip, a 2 race boat trailer w/ engines box, extra fridge, etc, etc .......  icon_ icon_crazy.gif   icon_problem.gif

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Re: Winter 44 Builds

Postby Fastjeff » Wed Nov 22, 2017 3:45 pm

You need a bigger garage!

Jeff

PS: Don't we all?
Words spoken in two stroke heaven: There's no fuel like an oiled fuel.
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Re: Winter 44 Builds

Postby zul8tr » Wed Nov 22, 2017 4:19 pm

Fastjeff wrote:You need a bigger garage!

Jeff

PS: Don't we all?


I need less stuff  :lol:
Pete
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Re: Winter 44 Builds

Postby ctpdsr » Mon Dec 18, 2017 1:39 am

A couple of thoughts along the way.

Now that the powerhead has made its way on the tower, I have access to the carbs and fuel system for some adjustments. Timing has been set, carb synch and throttle stops adjusted. Now to the choke rod assembly. These are not hard to make if needed. Political or Realtor sign frames make for great raw materials. Just use an original as a template and match the bends. The hard bit on twin carb set ups is to get the hole spacing just right. If you are off slightly, the covers will not line up and that is not good. After messing up on multiple occcasions, I settled on a method of drilling the bottom hole first, then mounting it in the carb asssembly to very carefully mark the top hole. Also, note the slight forward bend at the top? To assure the nice wide top choke knobs do not impact and thus ruin the paint job on a 1956-1958 starter top, it needs to be ever so slightly canted forwarded vs. vertical. I mean just slightly. Canted backward is bad bad. Making progress this week and looking forward to family getting home for the holidays!

Chuck
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Re: Winter 44 Builds

Postby dave bernard » Mon Dec 18, 2017 1:59 am

just make in two pieces like the electric choke models then it is adjustable.
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Re: Winter 44 Builds

Postby ctpdsr » Thu Dec 21, 2017 11:48 pm

Observation from the bench.

While looking for room on the pegboard to hang a new level, I found this bunch of timing belts removed from parts motors over the years hanging on a hook. Keep in mind about the same number of cracked or broken belts were thrown out over time and a few nice clean examples used on low budget projects. Guess I have been at this a while...For some reason, the ones with the fine blue lettering seem to be the best batch in terms of quality. Maybe they were newer replacements in the day?

Chuck
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Re: Winter 44 Builds

Postby ctpdsr » Mon Jan 01, 2018 1:34 am

Happy New Year!!

I enjoyed the afternoon in the shop putting some final touches on Jim’s 44.
A couple of notes to share. I never liked or understood the ugly factory side
mounts for the mag wires. Smart Tall Guy showed me how to custom trim each
wire so they lay within the lower pan. Looks way better and functions well. Key
is to keep everything in order. Also like to streamline the mag vents. One clear hose
on top and leave the other elbows turned South. Clean setup. The only modification
for race linkage would be to use a metal elbow on the left side to facilitate mounting
the return spring.

Chuck
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Re: Winter 44 Builds

Postby dndsam » Mon Jan 01, 2018 6:39 pm

Great work Chuck!  Another solid build that will out last us all, not to mention how awesome it looks!  I admire the attention to detail in your work!  Yet another student under the great 44ci professor demonstrating his skills.

Doug S.
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Re: Winter 44 Builds

Postby squirrelboydeluxe » Tue Jan 02, 2018 12:31 pm

Fantastic.
Love the plug wire routing. So simple!
How come I never thought of that? :oops:  icon_crazy.gif  icon_clap.gif
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Re: Winter 44 Builds

Postby Fastjeff » Tue Jan 02, 2018 4:37 pm

How come Carl never thought of that, and did it?

Jeff (whose Mark 78 is ugly wired as well)
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Re: Winter 44 Builds

Postby dave bernard » Tue Jan 02, 2018 5:26 pm

Carl's way is less chance of getting scuffed . just saying. not that it will in our life time.
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Re: Winter 44 Builds

Postby 58woody » Tue Jan 02, 2018 5:40 pm

Oily goo / moisture could get trapped down there and coat the spark plug wires.
I also moved away from the metal clips that Mercury used to hold the wires, the ones I now use are aluminum and rubber.

Regular maintenance of your mag for service and a thorough cleaning and all is good either way.
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Re: Winter 44 Builds

Postby ctpdsr » Thu Jan 18, 2018 12:03 am

I built this Merc 500 powerhead for my son Nick in 2007 for his GW Invader. He was honored to be on the JOMS 2017 Calendar with that rig at speed! We decided it was time to get a decent paint job on the lower cowl to try and match the factory original top and front plate (1956 Mk55 Quicksilver Green). I figured it could use a mag, carb and fuel pump rebuild after 10 years service. There will be a few notes on that to follow.

I have been told that mating a newer 40 or 44 powerhead to a MK40/KG9 non-shift tower was not uncommon in the 1960's for OPC racers when OPC stood for "Outboard Pleasure Craft". Guys with hulls like an AristoCraft or Dunphy that would not run with an H tower, but really benefited from the lighter non-shift foot & tower setups mounted high with trick high rake Johnson-Oakland props vs. a standard FGS MK55 or Merc300-500 series case. Note the fixed water tube in the MK40 tower and stock, unaltered MK50 lower pan make this an easy assembly. The performance and handling on a light hull like the Invader are awesome. You just need to be ready to go when you pull the rope! We do run a kill-switch with tether APBA style for safety,

Chuck
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Re: Winter 44 Builds

Postby Tom Brockmeyer » Thu Jan 18, 2018 10:42 pm

Some additional writings & restorations from ctpdsr is in this 2002 Antique & Classic Boat Society newsletter from 2002

http://acbs-bslol.com/boating-history/o ... urylegend/
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Re: Winter 44 Builds

Postby ctpdsr » Fri Jan 19, 2018 8:21 pm

Thanks Tom. Guilty as charged...

Seriously, I would encourage all of my friends here to check out their local ACBS Chapters. Many of the cool boat/motor combinations I have seen on this site would fit right in at ACBS shows and cruises. I was asked to participate in a show in 1987 in Albert Lea, MN by Bob Speltz who authored the "Real Runabouts" series of books after he ran across a photo of my Dad's Switzer Bullet in a local newspaper. The folks I met that weekend could not have been more welcoming. About 1/3 of the boats in the show were outboards. I was asked to return the following year to the larger show on Lake Minnetonka and help out on the Judging Committee. I enjoyed those events for years until my kids swimming sport became a serious deal travel-wise. The thing I was most impressed with was the fact that you could sit at a table with guys that brought $250K Gar Wood inboards to the show and all they wanted to talk about was how fast my little 14' AristoCraft could go and what type of propellers I was using! The boats are not limited to wood. Many entries were classic glass and aluminum boats. I know all club chapters have unique personalities, but it's worth a look. The Classic Boating Magazine (http://www.classicboatingmagazine.net/), in addition to being  very cool read, has a complete list of events as does the acbs.org website.

Chuck
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Re: Winter 44 Builds

Postby Tom Brockmeyer » Fri Jan 19, 2018 9:06 pm

Ok guys (& gals?)... Grab a cup of coffee, sit back and you can "binge read" most of the articles written by JOMS member, ctpdsr by clicking the following link.

Enjoy!  http://acbs-bslol.com/boating-history/outboard/
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Re: Winter 44 Builds

Postby dave bernard » Fri Jan 19, 2018 9:18 pm

About the rare finds.
I was lucky enough to find 3 of the 300 total Mercury long shaft Mark25L motors . That was luck.
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Re: Winter 44 Builds

Postby Toby Hall » Fri Jan 19, 2018 11:35 pm

Thanks Chuck for those enjoyable reads and Tom for sharing. You're dad's Switzer is glorious!  8-)
The stuff you can't see - That's what's important.
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Re: Winter 44 Builds

Postby ctpdsr » Mon Jan 22, 2018 5:12 pm

Thanks Toby. Dad is 83 and still gets in the boat once a year to prove he can still go fast! The MK40 is a factory sealed unit. I just service the carbs & mag from time to time...

Sorry for the typos in some of those old articles. Keep in mind I was mailing hand-written pages and photo prints to the editor who then re-typed everything. The "Boathouse" Magazine still get awards for a local ACBS Chapter publication.

Chuck
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Re: Winter 44 Builds

Postby Toby Hall » Mon Jan 22, 2018 7:22 pm

Chuck, I'm begging you to post some pictures of your dad and his Switzer and the Mark40! My D Raveau has Winnabagoland racing history.   icon_thumbup.gif
There is a Switzer B/C? on eBay right now. $$$$  
https://www.ebay.com/itm/PLYWOOD-BABY-BULLET-RACING-BOAT-HYDROPLANE-ANTIQUE-VINTAGE-40S-50S-13f-long/152873021470?ssPageName=STRK%3AMEBIDX%3AIT&_trksid=p2060353.m1438.l2649

(Side note: Bob Switzer passed away recently in FL...  He attended quite a few AOMCI meets.  -Moderator)
The stuff you can't see - That's what's important.
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Re: Winter 44 Builds

Postby ctpdsr » Mon Jan 22, 2018 9:00 pm

Don't think that is a Switzer on Ebay Toby. The term "Baby Bullet" gets to be used generically sometimes. The photo below is my son in a 1951 unmolested Baby. My MK25/KG7H hybrid on the transom.

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I will do a separate post soon on my Dad's boat. It has a neat story all it's own.

Chuck
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Re: Winter 44 Builds

Postby ctpdsr » Mon Jan 22, 2018 9:29 pm

Weekend progress to report. A few details on fitting the spark plug wires. I set the spool on my bench and with the mag temporarily mounted with an empty cap, measure each section one at a time. Pay close attention to the numbers on the cap, they are not in order! Allow a little extra slack for the mag drive travel. I like the long Mercury boots found on 25SS and 1970's Merc 500's the best, but have a limited stock. Mercury also used yellow wires in that era. To be 100% authentic, black Packard wires would be used, but I digress. The red Accel boots shown work fine as do the older Mercury versions - if they are not too dried out. I always use the old style Mercury coiled wire clips. Do a neat, even job of stripping the end and spread out the bare wire in a uniform star pattern over the tip just like the factory did it.

A couple of tools that really help with this job. The pointy scribe thing is something I use almost every day. Heck, spend a day in Jerry's shop and one would think he was born with one attached! It does a great job making the hole in the wire for the boot connection and cap screws. With regard to the later, this neat German screwdriver by Molybdan has a rotating top like a jeweler and fits those tiny brass screws perfectly. By the way, don't over-tighten those little guys. Break easily they can!

Chuck
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Re: Winter 44 Builds

Postby Yellowjacket » Tue Jan 23, 2018 3:05 am

Not a "Baby Bullet", but who knows what the history is on that boat...

Could be a Switzer but again, unless you had pictures from the day you're not going to have any real history on the boat.  

Actually it's a real mess, the bottom has been glassed and the glass slopped up the sides.  No idea what the deck wood looks like since it's been slopped with probably polyester resin when someone made a lake racer out of it.  You have to assume that it's all checked....

You'd have to be nuts to pay about 10% of the asking price for that.  Not to want to trash a seller, that price is particularly egregious...

JMHO and qualified as such....
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Re: Winter 44 Builds

Postby Fastjeff » Tue Jan 23, 2018 1:12 pm

Just be darn sure those wires are thoroughly "spiked" by the screw inside that cap!  I had one slip out as the distributor turned, which drove me nuts troubleshooting it since the wire went back into the cap and ran # 3 cylinder normally at idle.

Jeff
Words spoken in two stroke heaven: There's no fuel like an oiled fuel.
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Re: Winter 44 Builds

Postby ctpdsr » Tue Jan 23, 2018 5:37 pm

Good point Jeff. Also - don't forget the little rubber O-Rings. Be sure they are in decent shape and inserted well inside the cap. I use 303 Aerospace on these and all rubber stuff.

Chuck
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Re: Winter 44 Builds

Postby ctpdsr » Mon Feb 12, 2018 1:11 am

Just to confirm all is not surgical clean and pure in this shop, we have this stubborn MK 55A block. I want to use this for a future sport motor. The usually stressful exhaust cover came of with zero broken bolts. Yay!! Now on to the water jacket nut and bolt combinations. These fine thread bolts are always dirty and corroded, but not hard to remove. This was the worst I have ever seen. I admit I don’t see saltwater stuff here in Wisconsin, but this fresh water guy was a challenge. 100% of the bolts broke off and the bolts had to be center punched and drilled out. Then the bolt stubs left on the exhaust side had to be cut off with a Dremel wheel. Still had to use pry bars to get the cover off. I sacrificed it, but managed to get the block away unscathed. Not fun, but now we can clean up this block and add it to the assembly line.

Chuck
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Re: Winter 44 Builds

Postby ctpdsr » Sun Feb 18, 2018 10:59 pm

A couple of interesting discoveries while cleaning up some 44 pistons today.

First. I thought I had a nice matched set of early style light pistons for a future project. Not. While cleaning the ring lands, I noticed something missing! Anyone else out there run into this before?
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Next set is from a newer vintage. All looked the same at first glance. When I weighed them up, one was way off on the heavy side. Hmmmm. Upon closer inspection, you can see this guy has a much beefier internal casting. From a different batch altogether.

Always learning.

Chuck
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Re: Winter 44 Builds

Postby SteveC » Mon Feb 19, 2018 1:37 am

ctpdsr wrote:Just to confirm all is not surgical clean and pure in this shop, we have this stubborn MK 55A block. I want to use this for a future sport motor. The usually stressful exhaust cover came of with zero broken bolts. Yay!! Now on to the water jacket nut and bolt combinations. These fine thread bolts are always dirty and corroded, but not hard to remove. This was the worst I have ever seen. I admit I don’t see saltwater stuff here in Wisconsin, but this fresh water guy was a challenge. 100% of the bolts broke off and the bolts had to be center punched and drilled out. Then the bolt stubs left on the exhaust side had to be cut off with a Dremel wheel. Still had to use pry bars to get the cover off. I sacrificed it, but managed to get the block away unscathed. Not fun, but now we can clean up this block and add it to the assembly line.

Chuck
85AAD002-2C4A-4C1F-B62A-44BFB4A4437C.jpeg



I don't know if you have access to a TIG welder, but I found it to be easier to weld onto the broken bolts and back them out vs. the drill and retap method.  If I can save the original threads, I have had better luck with these.  I have a Wizard 2 cylinder block that had 17 broken bolts or studs in it, and I got them all out with this method.  (I thought it was a KE-7 block, and I had so much time into it that I had to use it on a KE-7, even though it is 18cid vs. 20.)  

Steve
2 KD-4s, 2 KE-4's, 3 KE-7's, 2 KF-7's, KG-7 rat, 3 KG-7's,2 KH-7's, 2 KF-5's, 2 Mk-5's, 4 Mk-20's, 7 Mk-25's, Mk-28.5, 3 Mk-10's , Merc. 450, 4 Merc.110's 63,68,68,69, 13 200's, Merc 60, Merc 800(71), & 1984 "D.U." 7.5
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