Sean's '59 Panel

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Dual Port
Posts: 1179
Joined: Fri Apr 30, 2010 10:06 am

Re: Sean's '59 Panel

Post by Dual Port » Wed May 13, 2020 10:46 am

Sean's decided to join the real world and ditch the 40hp in favor of a 1600SP. He'll now be able to get on the highway...….

It starts with a new Brazilian case, I've used these before and they're well worth the money. You don't have to line bore/thrust cut/lifter sleeve/deck cut/soda blast/clean and otherwise mess with a German case and they have upgrades like shuffle pins, case savers and an added oil drain for the flywheel seal, so now I don't have to drill a drain hole. I have this same case in the 2180 in Bus 1. Bus 2 has a NOS German case in it.
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They are thicker aluminum vs thinner magnesium which adds about 16lbs but that's no big deal.
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A fully trimmed engine is about 240 lbs. The reason I have a scale like this is for my cutaway diesel engines with a 3000lb limit, I know it's accurate because if I hang on the cable it shows my weight, 220lbs.
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Sean provided low mileage crank/rods/pistons/jugs/heads so I'll check each of those closely before it goes together. The crank mikes out really well, #4 journal is .0005" undersize but that's not going to concern me. No out of round, also. I don't have a lathe so I used a drill to spin the crank :shock: and polish it with 1000 grit, it looks really nice. I cleaned it thoroughly with solvent and a galley brush.
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The new case mikes out dead on both in size and out of round on all bores.
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After polishing and cleaning, the gears and bearings go on. I heat the gears with a lamp to about 250 or so on a halogen lamp. These things are so dangerous (because of heat) I can't believe we used them for so long. This is the only reason I keep it around, the gears slide right on when heated. Everything else I use these days is LED.
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It's getting the same cheater cam I run in my busses, the CB 2280. Oddly the specs are "almost" the same as mine. I polished the journals well on it too, because my 2180 showed wear on the cam bearings after only a few thousand miles with a new cam. You could see/feel the difference after polishing.
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Last edited by Dual Port on Wed May 13, 2020 11:34 am, edited 1 time in total.
Bruce Amacker
'66 Deluxe Bus
'65 Standard Bus

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Dual Port
Posts: 1179
Joined: Fri Apr 30, 2010 10:06 am

Re: Sean's '59 Panel

Post by Dual Port » Wed May 13, 2020 11:07 am

Everything went pretty smoothly for the first mockup, the crank set in, cam gear backlash was spot on, and I checked clearance to the CB Maxi Pump because usually there's a clearance problem there. In previous engines the cam bolts hit the pump body, on this one they did not but clearance was under .010". I ground the heads of the bolts slightly for clearance and torqued them with red Loctite.
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This is just mockup, not final assembly, I bolt the cam and crank in to make sure everything spins freely. I only use motor oil for lube on the bearings as that's how I was taught as a kid and that's what many mfrs state. Thicker lube can actually work against you on assembly, plus if you have a snug bearing you won't feel it with a heavy lube. I'll pre-lube the engine thoroughly through the filter flange before it's started. With oil the assembly spins as free as a bird, several revolutions when I spin it. Now it will come apart, rods and lifters will go in and seal up the case flanges. Oddly in the hardware kit I got doubles of a lot of things but no cam plug or bearing dowels. I have plenty of those. :mrgreen: Earlier Brazilian cases used a straight cam plug, now they're cutting them for an OEG style plug.
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Bruce Amacker
'66 Deluxe Bus
'65 Standard Bus

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