Green Tanker Build

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Green Tanker Build

Postby mercaholic » Fri Jan 05, 2018 3:11 am

I was sorting thru my parts bin to come up with this winter build.

Does anyone know if this combo of parts will bolt up or/and has anyone tried this ?

- KG4 (early) crankcase
- Mk20 cylinder block (ported exhaust)
- flat-top pistons from a Mk35A  
- Mk20 carb converted to gravity feed

My plan is to mount this on a fishing KG7 tower.
Attachments
greentanker1.jpg
greentanker2.jpg
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Re: Green Tanker Build

Postby TNT Teen » Sat Jan 06, 2018 12:31 am

I don't see why that wouldn't work. Using the ported block, might as well use a bigger carb if you can.
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Re: Green Tanker Build

Postby mercaholic » Sat Jan 06, 2018 1:07 am

I'm now realizing that the KG4 rods are somewhat unique such that fitting in a later piston design may pose a challenge getting the correct side clearance of the piston pins.

However, I will figure something out to make it work as I am looking forward to see how it breathes and if the extra compression will be noticeable.
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Re: Green Tanker Build

Postby Fastjeff » Sat Jan 06, 2018 1:26 am

If they are like the later 20/ 22 cube parts, the difference in weight (of the two different diameter pistons) is taken up by fat aluminum washers at the wrist pins on the 20 cubers, and thin steel washers on the 22 cubers.  This way Merc could use the same crankshaft for both motors without special balancing.

Jeff
Words spoken in two stroke heaven: There's no fuel like an oiled fuel.
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Re: Green Tanker Build

Postby mercaholic » Tue Jan 09, 2018 1:20 am

Struggled to get the correct piston pin washers (spacers) clearances and got it bolted up.

Lots to keep going on this.

Question:  were there flat top pistons available for the KG4/KG7 race blocks?
Attachments
kgflattops.jpg
merc200.1.jpg
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Re: Green Tanker Build

Postby rumleyfips » Tue Jan 09, 2018 12:31 pm

There were flat top pistons for the KG4/Mk15/Mk30 engines. 20 inch flattop pistons were produced for the 20H/55H . They would fit the KG7 but it was out of racing by then.
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Re: Green Tanker Build

Postby Fastjeff » Tue Jan 09, 2018 1:17 pm

See that fat washer he's holding? That's the additional weight used to allow lighter, smaller diameter pistons to use the same crank. The larger bore pistons use thin steel washers that are lighter to maintain the balance.  Pretty slick!

Found all this out building my Mark 78 when I tried to install Mark 75 pistons.  Doh!

Jeff
Words spoken in two stroke heaven: There's no fuel like an oiled fuel.
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Re: Green Tanker Build

Postby mercaholic » Tue Jan 09, 2018 3:04 pm

Jeff, with slightly heavier pistons from factory and the large washers all around, can I expect any balance issues for this block ?
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Re: Green Tanker Build

Postby Fastjeff » Tue Jan 09, 2018 10:22 pm

You could weigh the parts a do a bit of careful metal removal.

Jeff
Words spoken in two stroke heaven: There's no fuel like an oiled fuel.
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Re: Green Tanker Build

Postby zul8tr » Wed Jan 10, 2018 11:09 am

mercaholic wrote:Struggled to get the correct piston pin washers (spacers) clearances and got it bolted up.

Lots to keep going on this.

Question:  were there flat top pistons available for the KG4/KG7 race blocks?


What pin washer side clearance did you use   :?:
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Re: Green Tanker Build

Postby mercaholic » Fri Jan 12, 2018 3:21 pm

zul8tr wrote:
mercaholic wrote:Struggled to get the correct piston pin washers (spacers) clearances and got it bolted up.

Lots to keep going on this.

Question:  were there flat top pistons available for the KG4/KG7 race blocks?


What pin washer side clearance did you use   :?:


Just a few thous, enough to allow a small amount of lateral movement.
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Re: Green Tanker Build

Postby mercaholic » Fri Jan 12, 2018 3:23 pm

Installed the mk20 carb but now limited the advance by the fuel feed on top of the card.
Attachments
MK20CARB.JPG
Last edited by mercaholic on Fri Jan 12, 2018 3:38 pm, edited 1 time in total.
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Re: Green Tanker Build

Postby mercaholic » Fri Jan 12, 2018 3:31 pm

Tank tested yesterday while the temps allowed. icon_crazy.gif

I only ran it for half an hour to ease the break-in but still very tight.  

Compression is up to 110# on No.1 but only 104 on No, 2.

It sounds a bit more throaty but will need to wait until the spring to wring it out on the lake.

Note the ether can in the background.... icon_thumbup.gif .  Luckily I did not have to use it.
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flattopkg7.jpg
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Re: Green Tanker Build

Postby SteveC » Fri Jan 12, 2018 3:54 pm

mercaholic wrote:Installed the mk20 carb but now limited the advance by the fuel feed on top of the card.



On my "Greased Lightning" project, that has a lot of alignment with your build here, I tackled this problem by moving the fuel inlet tap to the side of the carburetor cover and plugged the inlet on top.  I had plug a vent hole on the inlet I tapped, but this allows the throttle handle to make the full travel.  

Steve

Hopefully I can get some photo's up to show you what I was doing.  I am using a Mk-25 barn door case, so it has the fuel pump boss on it, so I am planning to use a fuel pump anyway.  The tank will just be there to hold the recoil and look nice.... :D
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Re: Green Tanker Build

Postby Genel » Fri Jan 12, 2018 8:30 pm

Steve I would also like to see how you modified that carb. I would like to convert this one.
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0508161820-01 [134691].jpg
0508161819-00 [145849].jpg
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Re: Green Tanker Build

Postby mercaholic » Sat Jan 13, 2018 1:30 pm

Likewise
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Re: Green Tanker Build

Postby outboard315 » Sat Jan 13, 2018 3:12 pm

Brandon Cocola
Upstate NY
Mark 20, Mark 30H, WA25E, KG7H
14' Texas Maid, 12' Sea King, 12' Sea Nymph
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Re: Green Tanker Build

Postby SteveC » Sun Jan 14, 2018 5:12 am

We have been traveling back and forth to the hospital for the last several weeks, so I have not had much time to work on the motors.  I hope to get a photo up soon.

Steve
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Re: Green Tanker Build

Postby JW in Dixie » Sun Jan 14, 2018 2:51 pm

I have run both Mk20 and 25 stock carbs on gravity feed - no problem. Good luck with the motor and the health. JW
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Re: Green Tanker Build

Postby chuckw » Sun Jan 14, 2018 9:22 pm

Can anyone post pics of the conversion, specifically the hole for the fuel shut off valve and what it looks like in the inside of the float bowl. . I am going to convert an AJ47A to gravity feed. What tap size do you use? I have two shut off valves, one from an AJ32A and another from a KE7 ( I think). Which one gets used? Or can I use either one? Thanks for the help.
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Re: Green Tanker Build

Postby champhotrod » Sat Feb 24, 2018 7:21 pm

I have converted several pressure fed carbs to gravity feed. Use an
AJ47A or similar carb as the newer carbs have a better idle circuit. Had to buy a special tap for the bottom of the float bowl hole.
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Re: Green Tanker Build

Postby Bob » Sat Feb 24, 2018 10:15 pm

I have a dial compression tester, what type do you use to be that exact 110 and 104 ?
Thanks
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Re: Green Tanker Build

Postby SteveC » Sun Feb 25, 2018 7:27 pm

Sorry it took so long to get some photos of how I modified the carburetor cover to give me clearance for the throttle lever.  

What I did was to tap 1/8" pipe thread into the side of the cover where the vent hole is drilled.  I then added a new vent hole through the top of the cover, and put a flush mount pipe plug into the original top inlet.  I then drilled a hole from the new inlet to the center cavity above the inlet needle.  Then finally, I plugged the original vent hole from that inlet so the fuel would have to go through the needle/seat assembly instead of going through the vent hole.  

When installed, the throttle lever can pass above this for full travel.  The fuel hose will pass from the fuel pump and under the backside of the carburetor and up to the new inlet location.

Steve
Attachments
20180225_083610.jpg
Showing the new inlet path, with the new hole into the cavity above the needle/seat and below the newly installed plug.
20180225_083653.jpg
Showing the plug in the original fuel inlet hole, and the location of the new vent hole.
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Re: Green Tanker Build

Postby SteveC » Mon Mar 12, 2018 2:54 am

I posted photos of the installed carburetor in the FrankenMerc section.   viewtopic.php?f=64&p=130831#p130831

Project "Greased Lightning"

Steve
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