Thanks to the many of you who responded to the “mystery novel” that I turned last week’s update into and for putting up with my amateurish mystery writing skills. I was quite taken aback but most appreciative of how many of you enjoyed along with what I hope to be the final chapter in the great Serial Oil Pressure Killer series here on Möbius.World.
This last week most of my time has been spent putting Humpty Dumpty aka Mr. Gee all back together again with his new crankshaft, bearings and now FLAT oil pipework fittings installed and you can read all about that below. He is now back to ‘’bed” resting on his anti vibration mounts and I’m working my way through the rest of the assembly and adjustments so I can bring him back to life purring away in his Engine Room. If all goes well I should be able to share the first start up in next week’s update so do stay tuned for that.
Picking Up Where We Left Off
In my focus on telling the long and winding tale about tracking down the real oil pressure killer I skipped over most of the process of reinstalling the new crankshaft, oil pump, oil cooler tube and all the many other parts that I had disassembled so I will catch you up with al that now.
One of the only things we are not so fond of about our years here in Turkey is how much time, money and energy it takes to get things shipped into or out of the country. Not completely sure why this is and we do sometimes have things all go very well, but most often it is quite a PITA. Such was the case with getting the previous crankshaft sent back to Gardner Marine in England to be reground and then getting the new crank, oil pump, cooler tube and O-rings sent back to us here in Finike marina.
With the help of our ever resourceful “Turkish Fixer” Alaaddin, the latest crate finally arrived about two weeks ago.
The crankshaft alone weighs about 100kg/220lbs but Christine and I were able to get it out of the van and down the ramp onto the swim platform on Möbius without it going overboard.
and then slowly get him down the steps into the Workshop.
There are a number of parts that attach to the front end of the crankshaft such as a large disk vibration damper, triple row timing chain cog, roller bearings, etc. and these all need to be pressed or bolted onto the crankshaft. So I propped it up against the center workbench to do all this work.
This tag confirms the sizes of the Main Bearing and Connecting Rod or “Big End” bearing journals after they have been freshly reground and then the bearings are oversized by this same amount to match.
Protective corrugated cardboard is wrapped around each journal to protect the finely ground surfaces during shipping and installation.
To prevent the crankshaft from moving fore and aft there are two pairs of Thrust Bearings that need to allow no more than 0.006 – 0.009” of end play so you need to fit these to a newly ground crankshaft to get the exact fit. My good ole drill press often doubles as a vertical milling machine so I was able to use it again here to mill down each Thrust Bearing to just the right thickness.
I could do a dry fit of this and check the gap with feeler gauges while the crank was out of the engine and then once it was in place I could double check with a dial gauge as you see here. I forcefully tap the crank fully forward to zero the gauge and then fully aft to read the total endwise travel. Reading was about 0.0065” or “six and a half thou” which is just right.
Once I had the damper, roller bearings and chainwheel cog fully mounted I could start to carefully pull the whole assembly into the Engine Room.
A bit like an inch worm’s progress, I just took it a step at a time. It was probably now approaching 140kg/300lbs but I could lift one end by hand and so I put in some plywood ramps to help me slide the crank slide into the ER ………
…… then inch it over under the anxiously awaiting Mr. Gee who was “hanging in there”.
I rigged up a set of 6:1 blocks at the front and rear of the engine using Dyneema that I could wrap around the ends of the crankshaft and allow me to gradually pull it up into place.
To make sure the large hardened steel studs that clamp the main bearings in place don’t touch and damage the ground surfaces, I wrapped the threads with lots of duct tape and then carefully peeled off the corrugated cardboard covers.
Over on the workbench, I cleaned and prepped the main bearing shells in their big cast AL bearing caps.
Each of the AL bearing caps are press fit into the solid AL crankcase so I used a hydraulic jack to push them into place and then the cast iron Bridges slide over the two studs and the nuts are torqued down.
FYI, the small oval surface you see machined on each Bridge is where the infamously “bowed” fittings with the O-rings bolt in place.
Once I had the crankshaft bolted in place I could very carefully lower each Connecting Rod down onto their journals and bolt their bearing caps in place with the four bolts on each one.
Torqueing all these nuts down has to be done in a specific pattern as you progress through four different stages of increasing torque so that they are fully tightened and clamp the crank bearings precisely round.
Crankshaft is now fully in place with all cylinders attached and turning easily so I now turned my attention to installing the very critical timing chain and the hand crank chainwheel and water pump/alternator cogged belt pulleys on the front end.
Small and Light are never found in the same sentence with Gardner so I used the same inch work technique to get the massive solid cast AL oil pan/sump moved into the ER and in place under Mr. Gee.
I was able to reuse the 6:1 blocks and some webbing at the front and rear of the sump to pull it up into place and get it all aligned to slide onto the oil pump tube and the studs that attach the sump to the crankcase.
The flywheel is the most massive of all, not sure of its exact weight but I can tell you that it takes four burly guys to pick it up and it is all I can do to tip it upright when it is on the ground Fortunately the 6:1 blocks help me work smarter not harder and so once I got Mr. Gee pulled into the right position I was able to easily lift this beast up and into precise position to slide over the 6 end studs on the crankshaft.
With the flywheel torqued down I could now mount the aft half of its housing and then bolt on the large mounting brackets I had designed for the anti vibration “feet” or mounts to attach to on either side.
After carefully repositioning the overhead steel beams spanning the ER hatch up above, I was able to now lower Mr. Gee’s feet onto the Engine Beds for what he and I both fervently hope is the LAST time for a LONG time!
And now the wrestling match begins as I coax all of Mr. Gee aft to engage the big rubber cogs on the CentaMax torsion coupling on the Nogva input shaft to the matching AL housing on the Flywheel.
The blocks help me take off some of the weight and then lots of elbow grease and pry bars allow me to slide Mr. Gee aft little by little. Here I now have it all lined up with the cogs just engaged. You can see the 3cm gap that I still have to slide Mr. Gee aft to fit tight against the Brown Nogva case.
Done! Mr. Gee and Miss Nogva are now bolted back together and remarried for their new life together.
Next up is this new bit of engineering art and science from Gardner that was in the crate with the crankshaft. This is the copper engine oil cooler pipe where the oil is pumped through on its own circuit with its own oil pump. The “dimpled” pipe creates more surface area for the cooling sea water to flow around and extract out the heat from the oil as it flows through the tube.
Too bad this copper beauty has to be hidden away when I slide it into this cast Bronze housing but I’ve done my best to polish up the housing and give it a clear epoxy coating to keep it looking great for years to come. Who says you can’t have a bit of “bling” on a Gardner?!
Here is the engine oil cooler all reassembled. The cast Bronze housing on the closest end is where the oil enters and then runs through that dimpled tube inside and comes out the far end where it then drains back into the pan all nice and cool.
Sea water is pumped into the flanged fitting you see lying open in the near end here and then it flows inside the square cast Bronze housing and out the large diameter copper pipe elbow you can see on the far end.
Looking into that hole in the flange you see above, you can see the copper dimpled tube inside.
Sorry for the poor photo but if you look closely you can see the Bronze oil cooler now installed along the side of Mr. Gee on the left side of this photo.
I then connected all the white water hoses you see on the Right side here to various parts of Mr. Gee. Some of these carry fresh water to the heat exchanger which is like the radiator in a car or truck but uses sea water to cool rather than air. Other hoses cary salt water in/out of the engine oil cooler and the heat exchangers and the water pump. You can see through the clear lid on one of the sea water strainer in the mid Right side.
Big Black 5” Exhaust hose now reconnected to the large White water separator/silencer in the top Left corner and then down and out the ER where it connects to the AL exhaust pipe welded into the hull above the WL.
And that’s where we are at as of now (Jan 30th 2022) and where I will pick up with you again next week. Lots more parts and systems to reconnect and install but if all goes well I hope to be able to bring you a short video of Mr. Gee starting up first crank as he usually does and let you all hear the sweet sounds of a Gardner 6LXB purring away.
Thanks for joining and for your comments and questions typed into the “join the Discussion” box below.