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Thread: A bit of fill and antifoul will sort it out.

  1. #211
    Join Date
    Nov 2010
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    Wellington, NZ
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    769

    Default Re: A bit of fill and antifoul will sort it out.

    I've measured the Nissan and the Ford for comparison.
    The Nissan is;
    40mm lower, although the high point is at the front not the middle so probably a line ball for comparison,
    80mm shorter, so this may compensate for the taller front as well by sliding it back down the angle of installation,
    250mm narrower, which is significant as the offset cabin access is tight around the side of the motor.

    I'm toying with the idea of changing to a central cabin hatch, but will decide once I see it installed.
    The engine reconditioner I've spoken to thinks I will be saving about 100kg in weight.
    The engine mounts will take a bit of thought.
    The front ones will need steel fabrications using the bolt holes in the block.
    The very solid rear ones on the Ford are mounted on the Bell housing that Lees fabricated when they did the marinization.
    The Nissan has 4-5 unused bolt holes around the bottom semicircle of the bellhousing.
    I'm thinking about a 10mm vertical flat plate picking up those, welded and webbed to some heavy box section across the plate sitting on the engine bearers.
    The current setup is solid mounted, but I'm planning to use rubber mounts.
    This weekend I'll start stripping the Ford, aiming to get the head off for inspection and final decision on how bad it is.

  2. #212
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    Nov 2010
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    Default Re: A bit of fill and antifoul will sort it out.

    I was chatting with another yachtie yesterday about Haumuri's engine woes and the possibility of a used Volvo being available.
    He looked at a yacht with one in it to purchase that was 120 hp, and crapped out while out for a sea trail on a Pacific Island somewhere.
    It took a month for the engineers to sort it out, with a multitude of engine codes to trawl through. It turned out to be the low pressure diesel pump.
    He said Volvo have a pretty poor reputation around the Pacific with the charter guys and boat yard experts.

  3. #213
    Join Date
    Aug 2000
    Location
    Bay of Islands,N.Z.
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    27,405

    Default Re: A bit of fill and antifoul will sort it out.

    Lots of stories about the green death, but they're invariably modified versions of another engine anyway. But yes, the dealers /parts /servicing in this country is the big negative.

  4. #214
    Join Date
    Nov 2010
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    Default Re: A bit of fill and antifoul will sort it out.

    Today I spent some time stripping the old engine down, Partly to see what went wrong, and partly to make the engine easier to remove. Some almost before shots once I remembered to take some.
    [IMG]

    [IMG]

    [IMG]

  5. #215
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    Nov 2010
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    Wellington, NZ
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    Default Re: A bit of fill and antifoul will sort it out.

    It came apart surprisingly easily.
    I think it hasn't been touched since it got put in 45 years ago, because even though it looks like this on the surface, all the bolts are coming out shiny and clean.
    [IMG]
    Sorry, this one came out shaky, but the bores were clean and looked like normal wear, bit of a ridge but hey.
    [IMG]
    I wound it over and the other 2 cylinders looked the same.
    [IMG]
    The head looks OK with uniform colour through the 4 combustion chambers.
    I was starting to wonder if I had missed something like a water pump bearing or something.
    I then rocked the crank back and forward through the top of the stroke with the 2 middle cylinders up.
    Number 2 came up and smoothly dropped back down.
    Number 3 stopped and sat there for a few degrees or rotation.
    There was also a bit of a clunk while doing this too.
    So, it is the bottom end that is where the damage is.
    Apparently it must be pretty bad to be able to see it.
    You can see the sunlight hitting the wall of cylinder 4 in the last shot with some shadow, showing where the top ring stops at the ridge.

    I've now had 2 boaties say that they would not use the engine reconditioner that I've spoken to.
    They both had work done that had mistakes, and he wouldn't take responsibility.
    I may keep looking.

  6. #216
    Join Date
    Nov 2010
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    Default Re: A bit of fill and antifoul will sort it out.

    I've been working on the Nissan in the garage.
    The shed it is in does not have access for a trailer to lift the engine in, and it is uphill to the road.
    I've put wheels on the pallet so it can be dragged up the hill with a winch.
    I've been advised that long term storage of a diesel engine will not cause internal damage, so I am getting it set up to run it.
    After a bit of runtime, I'll measure compression and assess how difficult it is to start. I'll then decide if it needs a freshen up before installation.
    I brought home one of my start batteries from Haumuri and it is absolute toast. The other newer one was clearly doing all the work.
    Once that and the garden hose are connected, and the fuel hoses are dropped into a Gerry can I'm ready to annoy the neighbours!

    I need to figure a rear engine mount.
    The current setup has a very robust steel bellhousing with beefy mounts attached.
    I'm seeing 2 options for the new engine;
    1, Making up a plate that picks up the bottom half of the new bell housing bolts as mentioned.
    2, The Borg Warner Velvet drive has "mounting bolt holes" in both sides that look viable. The service manual calls them that, so I'm wondering if these can be utilised.

    Either option is about the same amount of work I would expect.

  7. #217
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    Nov 2010
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    Default Re: A bit of fill and antifoul will sort it out.

    Yesterday I wheeled the engine outside, got a battery and fuel container hooked up, then set up the garden hose into a bucket with the raw water inlet hose sucking out of it.
    It turned over OK but would not fire.
    I spent a bit of time bleeding the injectors, but wasn't getting much action. I blew out the lines to make sure they were clear (one was gummed up, but it cleared OK)
    That night I found information online that the injection pump needed to be bleed first via some screws in the side.
    I had an extra day off today to make a 4 day weekend, so I got rid of the air from the injector pump and bleed the injectors again. Now I was getting white smoke from the engine, but no life.
    I then disconnected and tested the glow plugs. They all were high resistance, so back online to find a supplier for a new set.
    I had to wait until about 3:30pm to get the call to pick them up, so $80 later I hooked 1 up directly to the battery to see how long it took to heat up. Sweet, 5 seconds.
    Once installed with cleaned up contacts, I gave it a try and the engine immediately burst into life as if it had last been started a week ago.
    I worked out that my Dad bought the engine and test ran it 15 years ago.
    It idled a bit rough for 20 seconds then settled down pretty steady.
    It was then that I noticed the smell of something getting hot at the front.
    The alternator wasn't spinning and the belt was sending up smoke signals.
    I stripped it down and freed it up. The iron in the coil had a little surface rust that was jamming it.
    So I'm ready for another test tomorrow, and I will give it a longer run.
    It starts better than the Ford ever did.
    I guess you get a win every now and then, even in 2020!

  8. #218
    Join Date
    Nov 2010
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    Wellington, NZ
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    Default Re: A bit of fill and antifoul will sort it out.

    A quick vid of a warm start after flushing the crud out of the water system, running with some flushing snake oil and refilling with the nice green stuff.

    https://www.facebook.com/639773459/v...7884141658460/

    Sorry about the quality there!
    I also fitted new gauges for temp and pressure (3.5 Bar at idle).

  9. #219
    Join Date
    Mar 2015
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    Perth, Western Australia, Australia
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    2,050

    Default Re: A bit of fill and antifoul will sort it out.

    Noice!
    http://fairmaid.blogspot.com.au/

    "It's dawning on me that I should have worked out the tumbler details more in advance, rather than rely on bluster and over confidence. But that's just silly." Jim Ledger.

  10. #220
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    Default Re: A bit of fill and antifoul will sort it out.

    Nice one Slacko - i was going to the pressure from the injector pump, but clearly i give in too quickly.
    It's all fun and games until Darth Vader comes.

  11. #221
    Join Date
    Nov 2010
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    Wellington, NZ
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    Default Re: A bit of fill and antifoul will sort it out.

    The injector pump pressure was the next area that I was looking at if the glow plugs were not successful.
    I bought them from a specialist diesel mechanic, so I got lots of free encouragement and advice along with the plugs.
    He said the injectors don't squirt that much out when cracked open, think about how little fuel they use in an hour of running.

    I'm now figuring out how to find and fit a V belt pulley to the more modern 90 amp alternator that I plucked from a Nissan Sentra at the wreckers.
    It is the correct body style, but has a multigroove pulley.
    The unit on the motor is 30 amps, which I don't see keeping the beer cold in summer.

  12. #222
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    Nov 2010
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    Wellington, NZ
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    Default Re: A bit of fill and antifoul will sort it out.

    I got the engine mounts manufactured by one of my mates. A bottle of rum and a box of beer should cover it. They are 10mm thick plate to give scale.

    [IMG]

    In the photo the "Zinc it" is partly dry, which is why they look patchy.
    I love this stuff, especially the touch dry after 20 minutes.
    I did some work in an ammonia plant, where we sprayed 316L stainless pressure transmitters with it so they didn't get eaten by the ammonia fumes. Anything that protects stainless gets my vote.
    I've since given them the first coat of enamel topcoat. 4 hours touch dry, Boo!

  13. #223
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    Nov 2010
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    Default Re: A bit of fill and antifoul will sort it out.

    I've also ordered online the correct pulley for the alternator.
    I just have to wait for it to arrive.
    Covid has dried up the supply of lots of things in NZ.
    I also need to get rubber mounts sorted tomorrow.
    Once these things are here, I'm ready to haul out and get on with it.

  14. #224
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    Nov 2010
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    Default Re: A bit of fill and antifoul will sort it out.

    The engine mounts on the engine have been fitted.
    The Port side one took a bit of work as the guys who marinised the engine used the forward most set of engine mount holes for the raw water pump mounting.
    The alternator bracket was also in the way.

    [IMG]
    It's all pretty tight in there, but I've shimmed the raw water pump so the pulleys line up nicely, and made a bracket from the pump mounting plate to the engine mount since this shot to hold it in place.
    I'm now figuring out how to make the belt tensioner. The one that was on it was rudimentary and almost impossible to adjust.

    This is a shot of the front showing the "new" alternator and it's pulley.

    [IMG]

    The pulley needed a bit of a spin on a lathe to make clearance at the back, but it fitted without having to move the mounting for the alternator which was a bonus.
    It is all loosely fitted in the shot with a bit of "zinc it" sprayed on the fresh water pump pulley.
    Once I've finished the raw water pump tensioner and buttoned up all the loose ends I give it another run to make sure it is still functional.
    I'm going to fit the new gearbox mountings while the old engine is still in the boat. This will give me the basic shaft alignment once the old engine is removed.
    I'll take the gearbox out as well and give it a cleanup and oil change. The oil cooler for this is going to need new pipework and the cooling circuit needs to be incorporated into the raw water system for the new engine. This can be worked out once it is all refitted.

  15. #225
    Join Date
    Apr 2005
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    Hills of Vermont, USA
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    36,623

    Default Re: A bit of fill and antifoul will sort it out.

    That is tight in there. Too bad you had to do so much fiddling - but glad you got it sorted!
    "If it ain't broke, you're not trying." - Red Green

  16. #226
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    Nov 2010
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    Wellington, NZ
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    Default Re: A bit of fill and antifoul will sort it out.

    Well, the belt tensioner now works with a screwdriver slot cut on the end of some M10 rod and a locknut once adjusted.
    I next went to the boat and started looking at the gearbox mounting brackets.
    The oil cooler was in the way so I took that off and brought it home.
    One of the steel pipes to the gearbox crumbled completely with a touch from a spanner.
    That was the next breakdown!

    This shows the cooler with the end caps off for a cleanout.

    [IMG]
    I've bunged the fittings to stop the oil dripping.

    The after photo showing shiny paint, new anodes and the remote oil filter arrangement on the bench.
    Not having the filter mounted upside down will save potential leaks into the engine bilge.

    [IMG]
    The AN10 and AN8 hose fittings, while not cheap probably work out about the same as brass hose tails (if you can find some), and are easily removable once fitted without battling hose clamps and rubber that has moulded to the hose tail.
    Shiny Too!

  17. #227
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    Default Re: A bit of fill and antifoul will sort it out.

    Nice clean up, well done.
    must feel satisfying!
    It's all fun and games until Darth Vader comes.

  18. #228
    Join Date
    Nov 2010
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    Wellington, NZ
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    Default Re: A bit of fill and antifoul will sort it out.

    Yep, the gearbox needs a similar tidy up too.
    Once the mountings for it are done, I'll probably pull the engine with the gearbox attached.
    I can then tidy it up and make sure it fits the new engine bell housing and thrust plate.
    Apparently they were set up for the gearbox.

    I met up with some of my old racing crew for drinks last week.
    They have been sailing a Ross 40 for a year or so in Auckland.
    The boat is now in Picton, just across Cook Strait so I suggested we do a regatta over summer on her.
    That wasn't going to work, but I now have a deadline of a regatta for Haumuri in Feb so I better kick on!

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