2.1 MV Rebuild DG case!!!

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Re: 2.1 MV Rebuild DG case!!!

Postby silverbullet » 06 Mar 2016, 22:06

Either/or

Both are non-acid cure ailicone sealant safe for alloys.

The Reinzosil is a bit easier to use thanks to the bigger tube & nozzle and the "sardine tin" key
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Re: 2.1 MV Rebuild DG case!!!

Postby silverbullet » 06 Mar 2016, 22:09

PS I put a bead in the bottom of the groove in the head seal as well as a small bead on the flat face.
Helps to guarantee a seal if the top of the water jacket wall is a less than A1
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Re: 2.1 MV Rebuild DG case!!!

Postby itchyfeet » 07 Mar 2016, 07:56

silverbullet wrote:PS I put a bead in the bottom of the groove in the head seal as well as a small bead on the flat face.
Helps to guarantee a seal if the top of the water jacket wall is a less than A1


I do both sides too, I suspect some water jacket failures is because just one side was done.
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Re: 2.1 MV Rebuild DG case!!!

Postby 123-jn » 07 Mar 2016, 17:29

Thanks for that, I wasn't sure if there was any difference!!!
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Re: 2.1 MV Rebuild DG case!!!

Postby 123-jn » 10 Mar 2016, 20:58

Well here goes the start of the build up. Still not sure if I have clearanced the case enough. Fingers crossed or it will all be apart again!!! Part one, case halves together tomorrow!!

http://s1275.photobucket.com/user/123-j ... q.jpg.html

As usual when I upload to P,bucket it puts my photos in reverse order.
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Re: 2.1 MV Rebuild DG case!!!

Postby itchyfeet » 10 Mar 2016, 21:02

looks very clean me.... except that spec of dust to the left of the thrust spigot :lol:
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Re: 2.1 MV Rebuild DG case!!!

Postby 123-jn » 11 Mar 2016, 22:13

Mark on the alloy I think, I see no dust!!! but I will clean all the mating surface with thinners before I put the sealant on. Here are my nice fittings to put the case together mixture of stainless bots with brass nuts and stainless nuts to go on the steel studs. Stainless set screws with dowty washers for the oil pump cover. You can also see my coolant elbow I have just made. I could not believe the cost of these (almost £50.00). I would have paid £20!!! I still need to make the other little one as that is quite pricey too.

http://s1275.photobucket.com/user/123-j ... 8.jpg.html
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Re: 2.1 MV Rebuild DG case!!!

Postby 123-jn » 13 Mar 2016, 16:22

I put the case together today, so a few more pictures here. Also I fitted my new zx6r exhaust to the van with its present engine, It has a deep sound not too loud. Really quite nice. I used blue Hylomar to seal the case trying to use as little as possible so as not to clog the oil passages.. I decided to coat the top part of the case(without the studs) as it was easier!!! I used a 2-3mm bead of hylomar and spread it out with a small flat brush.I used the yellow stuff from the gasket set to seal around the cap nuts in the water jacket and also around the case nuts and washers. Haynes said the 8mm nuts should be 20 NM and the 10mm ones should be 35NM for an early case. So I did 40NM for the 10mm ones and 25NM for the 8mm ones as suggested by the engine shop. Everything turns nicely.

http://s1275.photobucket.com/user/123-j ... f.jpg.html
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Re: 2.1 MV Rebuild DG case!!!

Postby 123-jn » 14 Mar 2016, 21:30

Piston rings tonight. These Grant rings are always a bit tight on the ring gap. Most of them 1st and 2nd were 0.25mm which is too small according to haynes. So I had to measure each one in the liner it is going in and file the ends. As I don't have a ring filer I used a file in a vice and some aluminium oxide paper. You must do this very straight and carefully as the rings must still meet perfectly when pushed together. After filing I used some alu oxide paper to carefully take off the burr formed without putting a bevel on the edges!!! Haynes says the 1st and 2nd rings can have a gap of 0.3 to 0.7. I did the top rings to 0.3 and second to 0.35 and am hoping this is enough!!! The oil rings were fine at least the top and bottom rails were at 0.5 with no filing. The centre convoluted springy thing is a nightmare. It almost seems too big and must not overlap at the ends. It will need to be compressed evenly all the way round as if you accidentally push it in too far one side the rails ping out of the groove the other side!!! I'm not looking forward to putting these in the liners!! I had the same make of rings last time and don't remember this issue. Top and bottom are both cast iron and oil control is chrome rails around the strange springy thingy!!

http://s1275.photobucket.com/user/123-j ... inersheads
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Re: 2.1 MV Rebuild DG case!!!

Postby silverbullet » 14 Mar 2016, 21:35

Use the [img] link (bottom one) from photobucket then the pics will show on the forum ;)
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Re: 2.1 MV Rebuild DG case!!!

Postby 123-jn » 14 Mar 2016, 22:02

Thanks for the tip on how to get the images on the forum, I wasn't sure whether that was a good idea or not. Didn't want to clog up anything :lol:
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Re: 2.1 MV Rebuild DG case!!!

Postby 123-jn » 16 Mar 2016, 16:46

I put the pistons in the liners today and cleaned out the breather tower. Pistons slid in a treat with a bit of a wiggle. considering I was worried about the oil scraper rings coming apart!!

http://s1275.photobucket.com/user/123-j ... o%20liners

THink I need more explanation of how to get these images on the post, Tried the last link on P-Bucket to no avail. Also tried hitting the img tab and dropping the image inbetween but I must be doing something wrong.
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Re: 2.1 MV Rebuild DG case!!!

Postby 123-jn » 16 Mar 2016, 16:50

Image

I think I may have got it!! Lots of nice oil slidy slidy.

Image#

Ready to go nice and tight in the compressor

Image

Give it a good firm push, I actually used both thumbs when not holding the camera, If it wont go a circular wiggle may work whilst pushing. If you resort to the hammer handle just gentle taps round in a circle on the crown. Don't whack it!!! you could bust the rings!!!

Image

layed out in pairs as they will go in the engine tabs facing each other, keep the arrows on top of the piston facing the flywheel end of the engine so to speak.

Image

Block waiting for it's pistons and heads.

Image
Image

THose of you with sharp eyes will have noted that it will be a DJ not an MV as in the title.
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Re: 2.1 MV Rebuild DG case!!!

Postby 123-jn » 24 Mar 2016, 14:47

Right so now it is circlips into the flywheel side of all pistons and then lube everything up, then fit them into the case.
Image

Give the grooves a good clean out
Image
ON with the black base seaLS
Image
Note the odd liner out with a bevel on the base?
Image
Ready to go in
Image
In with cylinder one Note the cloth to catch flying circlips
Image
Next one pin in through the water jacket hole
Image
circlip follows the pin in. You can have a screw driver down the middle of the pin to hold the little end in place while you wiggle the pin through.
Image
Right side done , note how the piston comes right to the top of the bore.
Image
Lubing up the piston bores
Image
And the pin
Image
And the little end
Image
Left side done
Image
Nice stainless outlet on the right side head.
Image
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Re: 2.1 MV Rebuild DG case!!!

Postby silverbullet » 24 Mar 2016, 19:43

All very satisfying! You wont regret building it to DJ spec, its a good strong performer even when wearing a carb on top.
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