Winter rebuild disaster ...Day 1

[john.p.clegg]

Dear All

Day 1 of the winter rebuild ( 5 speed gearbox needs bearings,weaker reverse blocking spring and camshafts re-timing)

Decided to give it a quick compression test before pulling the engine.....

1 2 3 4
Dry 170 180 185 90
Wet 180 200 210 120

Looks like I will have to take the head off....will check the valve clearances first

Want to make a spare water-pump module for the AKS front cover,this has been on un-molested for maybe 12 years.....even with the extractor screws it's not budging....so much for swapping the pump at the roadside,a little more gentle force and it looks like I'll have to make two,one to replace the damaged unit and a spare ( if anyone has a spare I'd be very interested.....or even any dimensioned drawings? )

If you have a cartridge pump it maybe wise to give it a good coating of copperslip etc to stop it seizing...

John

P.S. the cylinder numbers lined up with the readings before posting...but you'll get the gist

[john.p.clegg]

Day 2
Bugger,was lined up for a 36" set of Stilsons but paid an early morning visit to the local flea-market and picked up two pairs of stilsons one 14" one 18"....the larger of the two the jaws were too wide to fit between the pulley flange and the front cover but the other pair was a snug fit....even with a 2ft extension pipe I only managed to twist it about 10 degrees....well the pump capsule is now beyond repair...luckily I had a piece of 4" diameter Ali just waiting for the job...spent most of the afternoon on the lathe

John

P.S. anyone have a spare AKS module or the dimensions of one?

[AlfaLofa]

Hi John,

I have an AKS module which I have just refurbished - and it is still not fitted.

The depth A is 28mm
Diameter B is 66mm
C = 45.1mm (To back face of front plate)
D = 15mm (I.e. centre of ring to back edge of module)
E = 5mm (I.e. as above for other ring)
Diameter F is 48mm
Diameter G is 100.8mm
Plate width H is 7mm
The distance from the back edge of the module to the gap where the water flows is 23.8mm.

Finally the AKS bearing diameter is 30.0mm.

The first of these pictures shows the module before I fitted the seal (I ended up making my own !!).

I wonder if you could make an AKS module which takes the standard bearing? It would make it easier to use the standard seals - but problems might result from the differences in the overall lengths of the shafts.

If you wish I could send you my module.
Cheers, Steve

[john.p.clegg]

Steve

You are a star sir,probably not a good idea to send me your module,I'd be very loath to send it back,mine is nearly out ( in X pieces ) with the double O ring part still embedded....the next job is to make a replacement ( and a spare ) and as you say I am going to make it to fit the standard bearing and seals..

One again Thanks

John

Piccies to follow

P.S Be careful where you place the extractor holes,it's a bit thin near the water inlet and don't forget to give it a good coating of your favourite anti seize compound.

P.P.S.
I take it your shaft is not 1/2" each end?

[AlfaLofa]

Hi John,

You are correct - the shaft I have fitted has different diameter ends.

And yes I was careful with the positioning of the "thrust" screws.

If you get a production line going I'll take one off you for a fee

[john.p.clegg]

Out with the old

and in with the new ( well nearly)

John

[AlfaLofa]

Bl**dy Hell

I thought I had problems removing my module from the front cover.

[john.p.clegg]

as I said...

P.S Be careful where you place the extractor holes,it's a bit thin near the water inlet and don't forget to give it a good coating of your favourite anti seize compound.

John

[john.p.clegg]

Dear All
Day 5 and I must have been a very good boy this year as Santa has brought me ( early ) a new AKS front cover,backing plate and module.... so I can get on with the job of making two modules ( only got one piece of ali at the moment )

On the subject of AKS,did you know there are two types of front cover and two types of modules??

The differences of the cover are in the inlet waterway ( one has the front cover bolt passing through the waterway,the other has extra casting to shield the module bolt )


The difference of the modules is in the rear of the impeller housing, one is "stepped" the other is "flowed"

Also you can get the pump module with the orignal "Lotus" bearing or the later bigger bearing, all parts interchangeable

John

[john.p.clegg]

Day 6
After a few hours on the lathe and a hammer and chisel,nearly there....

using the standard Lotus bearing and the Lotus O-ring seal...

John