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Thread: Engine Rebuild step one

  1. #1
    Baby Twin dazzanna's Avatar
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    Engine Rebuild step one

    After two major disasters
    1/ big end faliure
    2/ the $3000 quote to fix it

    I decided to venture of and the fix disaster myself ...........
    and found s#*t loads of design faults which I intend fixing !

    Falco 2000 by the way !

    Ive started by getting the the crank machined and the rods rods
    closed and tunnel bored.

    Next.......... dremel in hand - fit Toyota 2k big end bearings !

    Then modify mains as to fix the oiling problem the crank suffers.
    .......Look up .... Design fault one !

    Followed by a decent yet cheap mechanical with hydraulic advantage
    timing chain tensioner .... Fault Two...

    If someone can tell me how the hell to upload pics I'd offer my progress !!

    Wish me luck
    Last edited by dazzanna; September 10th, 2009 at 01:11 AM.

  2. #2
    Baby Twin dazzanna's Avatar
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    Sorry ... " Crank main Suffer from "

  3. #3
    OZMILLE
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    Quote Originally Posted by dazzanna View Post
    After two major disasters
    1/ big end faliure
    2/ the $3000 quote to fix it

    I decided to venture of and the fix disaster myself ...........
    and found s#*t loads of design faults which I intend fixing !

    Falco 2000 by the way !

    Ive started by getting the the crank machined and the rods rods
    closed and tunnel bored.

    Next.......... dremel in hand - fit Toyota 2k big end bearings !

    Then modify mains as to fix the oiling problem the crank suffers.
    .......Look up .... Design fault one !

    Followed by a decent yet cheap mechanical with hydraulic advantage
    timing chain tensioner .... Fault Two...

    If someone can tell me how the hell to upload pics I'd offer my progress !!

    Wish me luck
    Interested indeed man, best way to upload is to join 'Photobucket'and upload your pics there, under each pic you have there are options, in the IMG CODE box just copy and paste that onto your post and its all good.

    Keep us posted with plenty of pics mate

    Best of luck my friend

  4. #4
    OZMILLE
    Guest
    Quote Originally Posted by dazzanna View Post
    Sorry ... " Crank main Suffer from "
    Where abouts you from??

  5. #5
    AMA Pit Boss supertedlover's Avatar
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    Would it not be easier to pickup another motor and drop it in ?

  6. #6
    Baby Twin dazzanna's Avatar
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    Falco rebuild

    From Australia !
    V60 engines can't be bought here for a reasonable price !!! ( if at all ! )
    And why buy another disaster ! ..
    I'll post pics of my progress and mods ( Photo bucket ? - Tomorrow )

    So many flaws ! so many easy fixes ----- I hope ----- Big ends good !!!

    Luck !

  7. #7
    AMA Pit Boss
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    I'm confused is the early Falco motor not the same as the early Mille as the early Tuono ??.

  8. #8
    OZMILLE
    Guest
    Quote Originally Posted by dazzanna View Post
    From Australia !
    V60 engines can't be bought here for a reasonable price !!! ( if at all ! )
    And why buy another disaster ! ..
    I'll post pics of my progress and mods ( Photo bucket ? - Tomorrow )

    So many flaws ! so many easy fixes ----- I hope ----- Big ends good !!!

    Luck !
    Mate, another Aussie!! Dont suppose your in Melbourne by any chance??

  9. #9
    Baby Twin dazzanna's Avatar
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    Stage one

    http://s696.photobucket.com/albums/v...t=CIMG0269.jpg

    http://s696.photobucket.com/albums/v...t=CIMG0294.jpg

    hope this works ...... The pics I mean ...... The second picture is of the K2 Bearings fitted .. Beer optional !

  10. #10
    Baby Twin dazzanna's Avatar
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    My rebuild

    If your interested in the costs so far ...
    1/ Machine crank - shut rods and tunnel bore $165.00
    2/ Toyota big end bearings ..... expect to pay $45.00
    3/ I expect to to pay $20.00 for the manual over hydraulic timing chain conversion !

    I'll keep you up to speed !
    Email if you need more.......

    Darryn

  11. #11
    DrRossi
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    Good work man!

  12. #12
    AMA Pit Boss AREESSMILL's Avatar
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    Keep going M8

    Interesting thread this one.

  13. #13
    Jussi
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    But you simply can not "tinker" with out beer.....

  14. #14
    Baby Twin R5vmille's Avatar
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    Why are you modifying for the Toyota bearings and not using Aprilia / Rotax ones?

  15. #15
    Baby Twin dazzanna's Avatar
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    The crank and the chain

    The cranks done !
    ( Aprilia don't make under size bearings )

    Manual timing chain adjusters / over hydraulic.
    $15.00 .. Bargain .. May have to lower the spanner side yet !
    "Gotta love those 16mm sump plugs from Repco"
    The adjuster bolt will be cut to length as when I know the optimum size.
    ( when the engines together ) and a head fitted or slot cut into it !

    "Foot note to fault 2" - who the hell puts a tensioner on the load side of a chain ? -

    Next the main bearing on clutch side of the crank.
    The oil feeder hole in the bearing is to be extended 1cm using a
    dremel - "big ends need friggin oil man" ridiculous that the big ends get
    oil pressure for a micro of a second every revolution ! [IMG][IMG][/IMG][/IMG]
    Last edited by dazzanna; September 10th, 2009 at 10:10 PM.

  16. #16
    DrRossi
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    Here you go !

  17. #17
    IanG
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    Well done Now this is what it's all about,too much of this ' what do you lot think of my shiny new levers' kind of thing.

    As one that's not yet had the pleasure of seeing inside a Rotax lump,what is the crank problem? not enough surface flow to the journal? I assume from your comments you are going to run a slot in the journal from the oil feed hole?

    Keep us posted please

  18. #18
    Baby Twin dazzanna's Avatar
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    Turns out

    Turns out oil feed isn't an issue ! ( Oops )
    Cranks on the back burner for a couple of days .... Not happy with the
    machining ! .. need new rod bolts also ... Will be in contact with ARP Monday to
    find an affordable automotive equivalent !

    Noticed questions on this forum regarding stator pullers-

    Grab an old cv from a automotive workshop ( check the size .. Duh )
    Cut the stub off - find big nut- weld ----- hey presto !

    "There are no problems - Only solutions"

  19. #19
    AMA Pit Boss AREESSMILL's Avatar
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    Way over my head now lol but keep giving us progress reports.

  20. #20
    Baby Twin dazzanna's Avatar
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    Budget blow out

    Re estimate of engine rebuild
    inc new rod bolts
    Timing chain tensioners .... Bargain $15.00
    Toyota Big ends
    Re machining .... again ...

    ...$500 usd
    ...Lots of those pommy pound things
    ...Or 15 cartons of Aussie beerdollars !

    Upload progress Wednesday ....

    Ontoit !

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