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Build update: Reassembling the Aerovee Part 2 May 2018


This time I got plenty of pictures.

With the case halves joined and each throughbolt torqued according the manual I moved on to preparing my new cylinders.




The cylinders and pistons got cleaned with laquer thinner, then oiled and then assembled together.

I used a specially measured shim places at the base of the cylinder to change how much space there is between the piston and cylinder head, which changes how the engine will run.

The shim goes on first, liberally gooped up with sealent, then slowly lower the cylinder on and connect it up







Then one it's on I turned the crankshaft to help pull the cylinder down, seat it with a few taps of a rubber mallet and done.








Repeat with the other cylinder and we are good to go.

Next goes the gasket, then the pushrod tubes, the head, aaaaand torque it!
      

Perfect! Now it's looking like an engine again.


Repeat on the other side







After careful measuring and lots of test fitting, the rocker arms fit great.


With the rocker arms just right, it was time to match the new pushrods I had bought to the rocker arm geometry, I used a special pushrod tool to find the exact length of an ideal pushrod, then cut my pushrods to the ideal length.






I marked the first one I cut as the master template with some blue painters tape. This way each new pushrod matches the master, not just some random pushrod I'd already cut. This reduces the chances of variation in the length.
After they were cut, I cleaned up the edge on the sanding wheel and measured against my master template to be sure they were precise.




Once all the pushrods were cut I ran hot water through them to clean out all the dust and shavings, and as soon as water touched the steel pushrods the timer had started and they began oxidizing. I liberally oiled every surface of the pushrods, and now it was time to insert the end piece into each pushrod. It's a very tight fit, so I needed to expand the tube, and shrink the end piece by heating and chilling respectively.






I torched each pushrod and immediately rammed the tip in, and they are good to go, I installed them in the pushrod tubes and they fit fantastically






Checking that the fit is whithin specs

Perfect, time to add the rocker arm covers






Now it's just a matter of installing all the small bits and pieces 



Oil pump!






Flywheel seal!




Block off plates!



I added the flywheel, exhaust and intake tubes, alternator, and mount but didn't get pictures of it.






Thanks so much to everyone who has helped me out, I cant wait to hear the engine spin up!

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