Day 7 - Engine

A small black pipe was added to the inside of the oil release valve.

A new breather pipe had to be cut bent and fitted to the inside cover.

 The badge was put onto the side cover, it has 3 small brass rivets and needed to be tapped in carefully not to damage anything.

New badge "T110"

Insulation tape protection!

Rogers purpose made "badge pin punch"

The rocker boxes needed to be assembled, which proved quite a challenge to get the process correct - almost like a puzzle getting the the sprung washers, washers and pin in the correct sequence. But in the end they looked great.

Another purpose made tool - chamfered interior edge to protect o-ring seal on rocker spindle.

Minor "surgery"

The valves were then installed in the head, the bottom cup were put in then the spring then the top cup washer then a valve spring compressor was used to compress the spring down and the 2 keys were inserted.

The whole way through where ever there are studs the holes were tapped and cleaned to make sure of a good fit for the studs. Studs were fitted with loctite.

The exhaust outlet manifold could then be fitted.

The piston rings were checked to see if the fitted the minimum clearance value which they did.

The oil drain pipe was reinstalled in the crankcase cover, and the filter fitting was checked in relation the the pipe and minor adjustments were made to ensure the right alignment.

The welsh plug was sealed and fitted in the end of the gearbox casing then the re-assembly of the gearbox could continue. 

We had to figure out which gears went were and the positioning of the camplate adjuster, it was quite tricky get the hole bunch of gears back in the box together but eventually worked out. The starter pin had to be rebuilt a bit as it had suffered some abuse in the past.