Topic: Sandcast 4286 Project

[Stev-o]

Glad you found the issue, Greggo.  When will you slap the motor back in?

[Greggo]

Next week I hope!  I left the top end disassembled so I can go back at it with fresh eyes to search for metal shavings, so I still have all that work to do, then getting it back in the frame is always fun, right!?

[Medyo Bastos]

bunnava#$%*ch!    glad things didnt turn out worse!

[markb]

I'm happy to see you found the problem too.  I know the feeling but the extra effort will be worth it for peace of mind.

[MCRider]

Be sure to use thread sealer on the 4 front stud holes, which are through holes to the atmosphere.

[Greggo]

Thanks guys, I'm cautiously optimistic.  I have more time and money into this bike than anything else I've done in life besides college.  I'm ready to put some miles on this one already, and I haven't had a good ride since I sold the '71 500/4...I miss that bike

Thanks for the heads up MC..I will seal those studs.  I'm also pulling the old/new/used/leakingAfter10miles pucks to replace with new ones and fresh non-hardening sealant.

[MCRider]

Great. Those 12 holes are problematic on heads that have been worked on, the 4 in front particularly.

I was educated on the pucks as follows (from discussions here): Some aftermarket pucks are not thick enough to do the job properly. Pays to use OEM or check the thickness of new aftermarket to see that they comply. You'll have to search for what that thickness really is, I don't have it handy.

Certainly, if you drop the puck into a clean hole it should stand proud of the hole, so that it wil squish when the cam bearing is dropped on. Use a short straight edge to test it.

(All my comments above are from first hand experience) 

[Medyo Bastos]

Great. Those 12 holes are problematic on heads that have been worked on, the 4 in front particularly.

 if you drop the puck into a clean hole it should stand proud of the hole, so that it wil squish when the cam bearing is dropped on. Use a short straight edge to test it.

(All my comments above are from first hand experience) 

i concur, experience cannot be easily taught

[Greggo]

This head came from Bill Benton, and had aftermarket springs and keepers...it had definitely been worked on

All six pucks stood proud of the head upon inspection, but the threads were unable to hold enough torque to seal the sandwich, especially right above the leaky puck where I could rock the 'tightened' bolt back and forth after removing the valve cover.  I'm replacing them with new Yamiya pucks as cheap insurance. 

[MCRider]

This head came from Bill Benton, and had aftermarket springs and keepers...it had definitely been worked on

All six pucks stood proud of the head upon inspection, but the threads were unable to hold enough torque to seal the sandwich, especially right above the leaky puck where I could rock the 'tightened' bolt back and forth after removing the valve cover.  I'm replacing them with new Yamiya pucks as cheap insurance.

Sounds good. 

[Greggo]

I appreciate all the help and motivation guys, this is why I keep coming back here!

[Stev-o]

I appreciate all the help and motivation guys, this is why I keep coming back here!

We wanna see this one back on the road!

[Greggo]

I appreciate all the help and motivation guys, this is why I keep coming back here!

We wanna see this one back on the road!

I hope you get that pretty H1 back on the road soon too, Stev-o!

[Stev-o]

I appreciate all the help and motivation guys, this is why I keep coming back here!

We wanna see this one back on the road!

I hope you get that pretty H1 back on the road soon too, Stev-o!

I've decided to do a full rebuild on the motor so it will be a couple months.

[Greggo]

I only had a little bit of time today.  I gave the head one last cleaning, then blew everything out with compressed air, and scanned it again for metal shavings and flakes.  The four head studs got their blue thread locker, all the head bolts were re-torqued, and the cam is back in.  The next step will be setting the timing. 

[Greggo]

Buttoned up with the valves adjusted.  I have to wait until next week when I can get some help lifting it and getting it back in the frame.

Sure felt nice properly torquing all twelve of those bolts!

[Stev-o]

And looks good too.

[Prospect]

Buttoned up with the valves adjusted.  I have to wait until next week when I can get some help lifting it and getting it back in the frame.

Sure felt nice properly torquing all twelve of those bolts!

I had to heli coil nine of the twelve cam tower threads when I tore my k1 apart.  I couldn't torque them down to spec otherwise.  Great work Greggo!

[David B]

I really respect your thoroughness and dedication to having it 100% the way you want it. Very admirable! 

[Greggo]

Seems like every damn thread wants to strip on this motor

#4's outside exhaust spigot screw got cross-threaded and I had to helicoil it.  I'm lucky to work in a shop where there just happened to be M8x1.25 helicoils and the 21/64 drill bit sitting around...I'm farking superman at this point feeling like nothing can stop me after fixing that..then when I was clamping down the last of the four oil hose to engine bolts down by the brake pedal that bastard decides to strip!  It was a short bolt, and I had a spare '8' head just about 5mm longer, which grabbed enough threads to torque properly   
So, I've got the whole bike back together oiled up but no gas because I ran out of time.  Next week if no gas leaks I'll put some miles down. 

I forgot to take a pic after putting the pipes back on it.




Oh, and here's the 23-window + sunroof van the shop bought yesterday.  The bear came with it, and stays with it. 

[Trad]

Looks great!

[SOHC4 Cafe Racer Fan]

Greggo,

Let us know when you manage to fire the bike.

Don

[Stev-o]

Alright Superman, were rootin for ya!

Those VW's sell for big bucks when restored, I don't get it, but I've never been a VW guy.

[toytuff]

HA! And you think the Honda was a project? 

Nice bus.

tt

[Greggo]

Alright Superman, were rootin for ya!

Those VW's sell for big bucks when restored, I don't get it, but I've never been a VW guy.

It's a numbers thing with these buses.  So many regular buses made, but not so many of these, which are even rarer than the 21-window version without the back corner windows.  And as time went on most of them crumbled away from rust, or got crushed because nobody cared for decades. This one is really nice as far as a starting point.  It's solid, and not very rusty.