DJ2.1 Rebuild

[maxstu]

Back on this Thurs or Fri. Driving to Bucks tomorrow, for a few days, to see my eldest sister about family matters. It must be important.

[Jilldub]

Doing a Grand job there Stu!
 

[maxstu]

Doing a Grand job there Stu!
 

Cheers Pete...

My engine post is a bit messy at present. Once l start the rebuild lm sure it will become more readable

How's the van going?

[Jilldub]

Hi Stu.
Van is going well.
 I am trying to get time to fit a new heater, controller, and EPS system.
 It’ll happen sometime soon

[Smiffo]

Back on this Thurs or Fri. 

Apologies Stuart - it was quiet on here, so I thought I'd play the clown 

[maxstu]

Hi Steve,

Have been busy sorting out other issues over the last two days'.

First, the front garden wall developed a crack along it pointing, leading to a wobbly wall. So much dust and grinding before repointing that area. Quite therapeutic to be honest.

Then the garden cabin roof developed a water leak. Sorted with high grade construction sealant.

And today l received a parcel from the lovely Isle of Arron, sent by Andrew at Campershack. THANK YOU THANK YOU!

One replacement (and matching in weight) DJ piston and pin, together with cam and crank gears to replace the original one's wrecked by TEC engine company....whom l would definately NOT recommend to any poor soul.



All this while suffering from a dreadful headcold.

And to finish for today, l placed a 190 quid order with Brickwerks, only for the order to freeze and my new replacement debit card getting rejected.

All in, a very eventful 48hrs.

Back on it Monday.

[Smiffo]

Hi Steve,

Have been busy sorting out other issues over the last two days'.

First, the front garden wall developed a crack along it pointing, leading to a wobbly wall. So much dust and grinding before repointing that area. Quiet therapeutic to be honest.

Then the garden cabin roof developed a water leak. Sorted with high grade construction sealant.

And today l received a parcel from the lovely Isle of Arron, sent by Andrew at Campershack. THANK YOU THANK YOU!

One replacement (and matching in weight) DJ piston and pin, together with cam and crank gears to replace the original one's wrecked by TEC engine company....whom l would definately NOT recommend to any poor soul.



All this while suffering from a dreadful headcold.

And to finish for today, l placed a 190 quid order with Brickwerks, only for the order to freeze and my new replacement debit card getting rejected.

All in, a very eventful 48hrs.

Back on it Monday.

Now I wish I hadn't said anything.
Get well soon mate - glass of red wine, and feet up for the weekend.

Rest up. The engine will be there when you feel better.

[maxstu]

Exactly what l'm doing!

[Stesaw]

Beatings will continue until moral improves

[maxstu]

This cold virus, whatever it is, is getting the better of me! Took a Covid test, resulting in a negative reading. So resting up for a couple of days' to get my strength back.
Brickwerks order submitted this morning at 0315am. Usual stuff....
Small end bushes
Big ends
Cam bearing shells
Oil pump cover plate
Piston circlips
Valve adjuster screws, plus much more.
Starting Monday with helicoil fixing in the sump drain hole.

[maxstu]

Feeling a lot better so back on the engine today.



Andrew at Campershack came up with a matching weight replacement DJ piston and pin. Plus the crank dissy and cam drives, too. Again, many thanks.

I gave the remaining three pistons a thorough additional cleaning (taking about 30-40 mins on each piston) before adding new rings. It's absolutely imperative to get the piston ring grooves squeaky clean, otherwise the ring compressor, needed to fit piston inside cylinder, will not squash the rings in far enough. Don't be too forceful, though.

I used an old piston ring and a small brass bristle brush from local Poundland.



Drive out carbon deposits inside the oil ring lubricating holes with a small screw driver or drill bit.




Then run around the grooves with old ring and tissue paper. Still lots of dirt in there!





Once happy with cleaniness l added new pistons rings. They need setting according to orientation and location of each piston.
Marked up No 4 piston. Arrow denotes towards flywheel (with rings already fitted)



Orientation of rings. L to R.
Top compression ring. Middle ring with gap at 180%. Upper oil ring ( just about see gap) oil scrapper with gap just below gudgeon pin hole. Lower oil ring with gap at 180% to upper oil ring.



All back in plastic bags and set on top of correct cylinders.



Note honing tool in foreground for new conrod small end bushes.

[Smiffo]

Good to see you back at it Stu!

[maxstu]

Fank quoo!

[Stesaw]

Honing conrod small end bushes??

[maxstu]

Honing conrod small end bushes??

Yep! Im going to use the early non-stretch conrods and fit new small end bushes.

From Brickwerks, they are supplied semi-finished. Push out old ones. Press in new. Then bespoke hone for each gudgeon pin.

New ground for me. So lve ordered two sets (8) small end bushes.

Also the sump plug needs redrilling, a tap and helicoil. Have ordered a blacksmith's (tapered shank) 14.28mm metal drill.