 Challenging Carb Repair, Weber 44 IDF |
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| ChrisFoley |
 Sep 20 2012, 09:38 AM
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#1
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I am Tangerine Racing  Group: Members Posts: 7,935 Joined: 29-January 03 From: Bolton, CT Member No.: 209 Region Association: None 
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We were having trouble tuning a customer's 2270 engine.
One cylinder would never idle properly but it would run at elevated rpm just fine. When we removed the carb to inspect it, we found that the idle mixture screw had been screwed in too hard, pushing the seat through the casting. It had been sort of repaired by glueing the seat into the hole, but the glue wasn't holding up too well and the seat was loose and misaligned. At first we attemped a simple repair using JB Weld to hold the seat in place, like the first repair. That worked for a little while, but the epoxy softened up from fuel and the seat came loose again. Rather than throw an otherwise good 44IDF in the spare parts bin, we made a permanent repair by boring out the carb base and installing a custom made sleeve. (you can see the edge of the broken out area around our 1/4" milled hole)  We used a short piece of 3/8" od aluminum rod found in our material storage area to turn a 1/4" od shouldered insert. Internally we drilled a shouldered hole for the seat to press into and tapped the insert with a M5x0.8 thread for the mixture screw.   The insert was installed with green loctite.    In the last picture you can see the drilling for fuel to the mixture screw that goes from the bottom of the carb base into a passage cast into the carb body. The bottom end of the hole was plugged with lead. We drilled up through the newly installed insert, and resealed the bottom of the hole with a short aluminum plug and a little JB weld for final seal. |
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| FourBlades |
Sep 20 2012, 09:46 AM
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#2
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From Wreck to Rockin Group: Members Posts: 2,055 Joined: 3-December 07 From: Brevard, FL Member No.: 8,414 Region Association: South East States
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Wow, nice repair! John |
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| rhodyguy |
Sep 20 2012, 09:53 AM
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#3
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Chimp Sanctuary NW. Check it out. Group: Members Posts: 22,093 Joined: 2-March 03 From: Orion's Bell. The BELL! Member No.: 378 Region Association: Galt's Gulch |
very cool. that ias had to have been reefed on by a gorilla.
hey. how did "win" in my sig get changed to blue and underscored? i didn't do it. |
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| mrbubblehead |
Sep 20 2012, 02:12 PM
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#4
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Twodollardoug Group: Members Posts: 1,155 Joined: 17-December 10 From: calimesa ca. Member No.: 12,492 Region Association: Southern California |
nice repair chris (IMG:style_emoticons/default/beerchug.gif)
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| SUNAB914 |
Sep 20 2012, 02:35 PM
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#5
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Senior Member Group: Members Posts: 698 Joined: 29-December 08 From: Fredericksburg VA Member No.: 9,880 Region Association: South East States |
great, does it work now?
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| ChrisFoley |
Sep 20 2012, 06:51 PM
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#6
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I am Tangerine Racing Group: Members Posts: 7,935 Joined: 29-January 03 From: Bolton, CT Member No.: 209 Region Association: None
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QUOTE(SUNAB914 @ Sep 20 2012, 03:35 PM)  great, does it work now? Much better now. (IMG:style_emoticons/default/smile.gif) Idles smoothly at 900 rpm on all 4. |
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| cgnj |
Sep 20 2012, 07:06 PM
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#7
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Senior Member Group: Members Posts: 627 Joined: 6-March 03 From: Medford, NJ Member No.: 403 Region Association: None
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Hi,
So how much to do this repair on a buried air bypass screw? Have a spare set of dell 45s in a box. One has with this problem. Thanks, Carlos |
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| ThePaintedMan |
Sep 20 2012, 09:27 PM
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#8
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Advanced Member Group: Members Posts: 3,886 Joined: 6-September 11 From: St. Petersburg, FL Member No.: 13,527 Region Association: South East States
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Pretty cool Chris. Your engineering skills never cease to amaze me. BTW, I have a couple spare 44 IDF bodies if you are in need of spares.
-George |
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| euro911 |
Sep 20 2012, 09:59 PM
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#9
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Retired & living the dream. God help me if I wake up! Group: Members Posts: 8,851 Joined: 2-December 06 From: So.Cal. & No.AZ (USA) Member No.: 7,300 Region Association: Southern California
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| ChrisFoley |
Sep 21 2012, 08:06 AM
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#10
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I am Tangerine Racing Group: Members Posts: 7,935 Joined: 29-January 03 From: Bolton, CT Member No.: 209 Region Association: None
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QUOTE(cgnj @ Sep 20 2012, 08:06 PM) Hi, So how much to do this repair on a buried air bypass screw? Have a spare set of dell 45s in a box. One has with this problem. Thanks, Carlos I looked at a 40 Dell I have here. Seems like a similar repair would take about the same time. Nearly 3 hours, or around $250. |
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| gothspeed |
Sep 21 2012, 03:46 PM
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#11
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Senior Member Group: Members Posts: 1,539 Joined: 3-February 09 From: SoCal Member No.: 10,019 Region Association: None |
Looks good ..... (IMG:style_emoticons/default/smile.gif)
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| RS22b |
Sep 21 2012, 05:58 PM
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#12
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Type Broken! Group: Members Posts: 223 Joined: 8-January 05 From: Vernon, NJ Member No.: 3,425 |
Looks good Chris! Thanks for saving it!
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