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techtalk:ih:engmech01a [2018/05/16 20:39] hippysmack created |
techtalk:ih:engmech01a [2018/05/16 21:02] hippysmack [IH: Engine Mechanicals - Sub-01A] |
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| ====== IH: Engine Mechanicals - Sub-01A ====== | ====== IH: Engine Mechanicals - Sub-01A ====== | ||
| + | ====== Sprocket Cover Dowel Hole (Case) Repair ====== | ||
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| + | * This is a bit of an obscure one but a real pain to fix, requiring several special tools. This was also done with the cases assembled. If had split the cases I could have put them on my mate's milling machine and precision machined them. But because I was too lazy to split the cases and disturb that nice tight, factory original bottom end, I did it the hard way. ((Hopper of the XLFORUM http://xlforum.net/forums/showthread.php?t=395586)) | ||
| + | * When it came back from the aircraft welder it looked like the pics below. | ||
| + | * Amazingly, there was no big blob of weld but two tiny little rings, still with the (rough) hole in the middle. His TIG welder can weld aluminum .010" thick. | ||
| + | * The gearbox shafts and bearings were left in place during welding to help stop distortion of the cases. | ||
| + | * He pre-heated the cases gently with a torch and then he would put a ring of weld on, let it cool off, repeat, repeat repeat etc. | ||
| + | * Notice how he welded around the screw next to the top hole but did not go over it. And the 1/4" threaded hole in the middle was still useable. | ||
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| + | |{{:techtalk:ih:engmech:sprocket_cover_dowel_hole_repair_1_by_hopper.jpg?direct&400|}}|{{:techtalk:ih:engmech:sprocket_cover_dowel_hole_repair_2_by_hopper.jpg?direct&400|}}| | ||
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| + | * Now all I had to do was re-machine those two 7/16" dowel holes back where they should be within app. .001". | ||
| + | * First thing was to file the flat surfaces back on again, using the sprocket cover with bearing blue on it as a guide. A couple of hours with a pair of 10" bastard file and millsaw file did that. | ||
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| + | |Here's a drill jig made from a half-inch steel plate to guide the drill| | ||
| + | |{{:techtalk:ih:engmech:sprocket_cover_dowel_hole_repair_3_by_hopper.jpg?direct&400|}}| | ||
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