My generator refurb

[solarman216]

Forced on me a bit quick as it has a seized bearing, while it is apart I hope to fit the flywheel from an older SR2 that has a ring gear in order to be able to use a conventional starter motor, here is the old mini flywheel puller being put to good use as this flywheel is also on a taper but this made it a doddle together with a good whack with a hammer

 

[solarman216]

Off

 

[solarman216]

A bit of a clean up, not as good as wanted because the genny will not run my air compressor properly now, not sure quite why that is, as genny feels free enough when turning over by hand but with magnetic field when running it may be fouling some place, so hope to start stripping it down this evening as got to get the armature into the machine shop to have the shaft turned down and a sleeve put on ready for the new bearing, this little beast is so heavy I can only just lift it off the ground, Rick

 

[solarman216]

Ah so one of the las picked it up today no problem so I am showing my age, gone are the days I could pick up 50kg cement and sling it on my shoulder, remember when I first started driving had to pick up 20 ton of flour in London docks it came down a chute at the end of the trailer you had to catch it on your shoulder and at the start of the load fun the 40 ft to the headboard and stack it, and also get back to the chute before the next one came down, if you missed it and it landed on the bed it would burst open you then had the mess to clear up as well, Ha Ha bygone days, gonna get cracking on the gen set today, got to rig a scaffold hoist as no way can I lift it, Rick

 

[jims-terrano]

Still have to take my hat off to you Rick not having an electric bill.

 

[Banshee]

Fascinating stuff Rick, can't wait to see your setup one day :thumb2

 

[solarman216]

All heavy and awkward work, however got the alternator separated from the engine and lifted to working height

 

[solarman216]

Some of the wires that needed to be disconnected and detailed before hand

 

[solarman216]

Com end connections brushes and slip rings

 

[solarman216]

Com end off

 

[solarman216]

Armature out, heavy barstuard

 

[solarman216]

The worn bit, big problem is with the circlip grove, not sure at the mo how we can overcome that, as once it is turned down to to accomodate a sleeve, if the groove is re machinedit will likely cut the sleeve through, no good it may be they can weld it to hold it in place, but my favourite is to have a second sleeve made but larger outer diameter so that it crampes the race inner with a washer and bolt into the centre hole on the shaft, it already has a thread in it, we will see what the engineering shop says tomorrow

 

[solarman216]

The stator

 

[solarman216]

The hoist used to lift it, we used this same hoist to lift a 47kg gas bottle on to a roof a year or two ago but would not lift this lump without a block, tomorrow will see delivery of the rotor to the machine shop, then I will be looking at ring gear issues, I see the existing flywheel is machined for a gear but none fitted, the current price for one is £165 so no way will I be paying that, I am hoping that the wheel off the SR2 will work but think maybe the fan is not big enough as for a 2 cyl and mine is a 3, might be able to swap the fan but then get into balancing issues as they are balanced once assembled, next option is to destroy the 2cyl wheel and salvage the ring gear, time will tell, Rick

 

[panelbeater]

love these picks rick.

 

[solarman216]

Turns out now I have my f/wheel off that they are both the same part number, it is just the bolt on fan that is different, so thinking that I will try the Sr F/wheel with the ST fan and cos it will now work with a starter motor, run engine up on it's own and see how it is, on another note the flexi drive coupling is in a sorry state and I found this today which I thought was perfect but it is a couple of mm out on the bolt centres, so now not so sure, but found a company on line that supplies lots different rubber doughnuts so sent them my requirements, will wait and see, good news is machine shop has done the sleeve, so pick that up in the morning, Rick

 

[solarman216]

So got rotor back today nicely sleeved complete with clip groove, £150 for the job, sounds expensive but these guys are quality machinists, and same old story use them or lose them, this kind of work is getting rarer

 

[solarman216]

New SKF bearing on and clip, the outer shield will be removed when outer casing goes on so can be greased via nipple, keeping it on for now to protect it from crap

 

[solarman216]

Original flywheel no gear

 

[solarman216]

Donner wheel with gear, but fan removed