Tuesday, July 26, 2011
Monday, July 18, 2011
Friday, July 15, 2011
Fri., 15 July, 2011 I finally got the flywheel off the crankshaft of my Dondolino. My friend Erik Green, proprietor of Works Engineering in Brooklyn, had a proper hardened 5/8 X 18 bolt from a puller that we used in the tool Jerry Kimberlin had made to thread into the flywheel hub. We hit it with two different pneumatic impact guns he had and it didn't budge. We heated it with the oxy-acetalyne torch: nothing. While periodically shocking the flywheel with a hammer, we used a 1/2" breaker bar and a 36mm box wrench with long pipes over each and pulled on them until we broke off the bolt. So, we removed the puller tool and set the whole driveside crankcase half, flywheel and crankshaft up in a 150 ton press. This involved stacking up a bunch of spacers under the flywheel, which touched the flywheel on it's perimeter at not quite 180 degrees. Definitely not the ideal setup. We pressed on the end of the crank and, I swear, one could see the flywheel flex. Finally, when I was sure the flywheel was going to break, it let go with a tremendous bang and the crankshaft ejected downward. Amazingly, nothing seemed to be damaged any more. The tapers of the crank and flywheel aren't that bad and I'm sure can be lapped. It looks like it's going to be a bit of a challenge to get the sheared key out of the crank and I'll have to check that the crank's not twisted, but I think it all can be used again. I'm really impressed with the strength of the flywheel. I can't say I recommend this method, but it did work and nothing (and no one) was hurt, proving once again that brute force and ignorance made this country great.
Sunday, July 10, 2011
10 July, 2011 While I still haven't got the flywheel off the crankshaft even with an improved puller, I decided to pull the motor out of the frame and split the cases. I thought this would make it more portable and give me access to the crank to maybe try to cool it while I heated the flywheel. It appears that the gearbox is fine and I can't see anything wrong with the crankshaft other than it's welded to the flywheel. The crankcases don't look too bad and I think they're worth trying to weld and re-machine. In the photo of the drive side crankcase with the broken rod, you can see the big aluminum ring and the extended cyl. studs that thread into it. This was done sometime in the distant past to repair a crack in the case. In the photo of the timing side case, you can see the front, upper case bolt that took a direct hit from the broken rod. I've since cut, ground, and drilled this out of the case.