DJ rebuild... piston damage....

Big lumps of metals and spanners. Including servicing and fluids.

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spanishfly
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Re: DJ rebuild... piston damage....

Post by spanishfly »

Cleaning continues..... as does the search for a cam. 

The Camshaft journals? saddles? if that's the right term at either end are smooth and cleaned up with a green kitchen scotch, but the 2 central ones have a track of wear each. Is this a disaster? Image

Also having dug deeper and seen many other similar posts the Camshaft issue is omnipresent! 

There don't seem to be many comments about german reprofiled (very expensive) cams, are they a complete waste of money?

Worse than a chinese blanked option?



 
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Stesaw
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Re: DJ rebuild... piston damage....

Post by Stesaw »

Message Ajsimmo, he should hopefully be able to sort a new cam for you.

Those bearing housings look very clean crikey, maybe I should revisit mine to be sure before putting the case together!

If you have an air compressor blow through the oil passages, you don't want any rouge bits of metal in there to mess up your new shiney bits! do the same on the crankshaft oil holes, I am paranoid I haven't cleaned them enough even though they've been diped and cleaned and cleaned and clea....

Get a closer picture of those wear bits if you can, I don't think they make a difference as the cam will be sitting on new bearings and not the housings. The case has the cutouts for the tangs on the bearings that seat them in place so as long as they are OK I don't think you should have a problem. But that's my ignorant opinion, for all I know it could affect oil pressure.

I would never buy chinese for components, especially engine bits. Cheap is never a good alternative to quality, as much as your wallet might cry on the latter. 


 
1985 LeisureDrive 2.1DJ 5 Speed syncro conversion project.
1979 LT 2.0CH Westy project

spanishfly
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Re: DJ rebuild... piston damage....

Post by spanishfly »

Thanks, I don't but there's a BP station opposite so may take it for a walk.

And you're right about the rogue bits of metal the bits of wire from the dremel brushes are plain evil, I've found them embedded in my hands, my scalp, causing me to yank out hair I can ill afford to lose and rather scarily after rediscovering a half nibbled biscuit one embedded itself in my tongue triggering a swallow response that threatened to send it down my throat! They're so fine you don't feel it until they snag on something, ouch!  :?
1987 Westy Joker 1.6TD
1987 Dehler Profi 2+2
1988 Syncro RHD panel
 

300CE
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Re: DJ rebuild... piston damage....

Post by 300CE »

If the funds permit Spanishfly, I’d look at a Marco Mansi Oil Pump from the US to complement your rebuild - it’s going to be next on my list at some point and wish I’d got one with the rocker kit (scroll down about halfway):

https://mansispeed.com/products/
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spanishfly
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Re: DJ rebuild... piston damage....

Post by spanishfly »

Funnily enough I have one waiting in the wings, purchased when I had less cleaning time on my hands! I haven't checked but thought it was 30mm? So dependent on sourcing a decent original camshaft or have i got that wrong?
I did port the heads yesterday which was enjoyable, hopefully that might help. 
 
1987 Westy Joker 1.6TD
1987 Dehler Profi 2+2
1988 Syncro RHD panel
 

spanishfly
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Re: DJ rebuild... piston damage....

Post by spanishfly »

Love hanging the washing out!Image
1987 Westy Joker 1.6TD
1987 Dehler Profi 2+2
1988 Syncro RHD panel
 

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Oldiebut goodie
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Re: DJ rebuild... piston damage....

Post by Oldiebut goodie »

That's the only sort of washing that I hang out! :ok
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spanishfly
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Re: DJ rebuild... piston damage....

Post by spanishfly »

Not sure it did the machine much good!   Image
1987 Westy Joker 1.6TD
1987 Dehler Profi 2+2
1988 Syncro RHD panel
 

TONYT25T25
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Re: DJ rebuild... piston damage....

Post by TONYT25T25 »

Must make a nice sound when the wind catches them. :rollin
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spanishfly
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Re: DJ rebuild... piston damage....

Post by spanishfly »

Like a DJ!
 
1987 Westy Joker 1.6TD
1987 Dehler Profi 2+2
1988 Syncro RHD panel
 

spanishfly
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Re: DJ rebuild... piston damage....

Post by spanishfly »

One step forward.... Imageone step back.......!Image
1987 Westy Joker 1.6TD
1987 Dehler Profi 2+2
1988 Syncro RHD panel
 

Stesaw
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Re: DJ rebuild... piston damage....

Post by Stesaw »

Yep they are a bugger. The worst job I had to do on mine as well.
1985 LeisureDrive 2.1DJ 5 Speed syncro conversion project.
1979 LT 2.0CH Westy project

spanishfly
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Re: DJ rebuild... piston damage....

Post by spanishfly »

I don't feel like i got enough heat in with cannister torch, base of the stud was half way nibbled away already and didn't really change colour after 8 mins of heating. 

I am a bit confused though, cue eye rolls but as i understood it these pages seem to suggest heating the stud to cherry red is a good idea but surely that causes it to expand and makes it tighter?

Shouldn't I be aiming to miss the stud and heat around it?

And if so where around it/them is safest?  :oops:
1987 Westy Joker 1.6TD
1987 Dehler Profi 2+2
1988 Syncro RHD panel
 

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Oldiebut goodie
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Re: DJ rebuild... piston damage....

Post by Oldiebut goodie »

Personally I would heat the alloy and use freezer spray on a stud before attempting but those engines are a law unto themselves.
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Stesaw
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Re: DJ rebuild... piston damage....

Post by Stesaw »

If the studs already have a lot of pitting then they are more then likely going to snap no matter what you do. You can cut them down to reduce the lengths so there is less twist but again if they are in poor condition then you might struggle.

I dont think you'd need to get anything that hot. Sure they would expand if they were that hot but I suppose doing that would be to break any corrosion on the threads of the stud and the block. The idea of heating as I understand is heating the block and not the stud, so heat the area around the stud base rather than the stud itself, then once heated give the top of the stud a tap with a hammer/mallet and dump some Plus Gas or other penetrant around the base of the stud. Normal WD40 will not suffice.
1985 LeisureDrive 2.1DJ 5 Speed syncro conversion project.
1979 LT 2.0CH Westy project

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