Engine GA000099, An early GA engine rebuild thread Options

[Superhawk996]

Last week I bought engine GA000099 from Freezing914 in the hopes of picking up some spare parts to support rebuild of the engine that came with my vehicle.

During the teardown of my vehicles engine, it is quickly becoming clear that the engine was abused by some DAPO. Cooling flaps and thermostat had been removed. Rust in the sump. The crank was scored and already 0.010" undersized. The oil pump was torn up. This is just the tip of the iceberg on the engine that came with my vehicle. (IMG:style_emoticons/default/chair.gif)

14 hours of driving seems to have netted me an engine that might be worthy of a rebuild. (IMG:style_emoticons/default/piratenanner.gif)

This engine appears to be bone stock. D-jet mostly complete. As an added bonus I discovered upon teardown that none of the cooling tin fasteners have ever been disturbed. No screwdriver marks!

But . . . like any engine of this age and unknown origin, it absolutely needs to be gone though.

[Superhawk996]

Here's a continuation of the case machine work that is ongoing on this GA000099 case and GA004310. It's easier to do both cases simultaneously as batch work to minimize set up time.

There are 11 galley plugs on each case that need to be bored and tapped. Tonight I managed to get six on each knocked out on each case.

The 3/8" NPT plugs are a bear. Due to the size of the tap and especially since they are cutting a tapered bore out of stright hole, they take a lot of muscle to get them tapped to the proper depth. This job would be a whole lot easier if I had a NPT tapered reamer to clear out some of the material but I don't so it's just a good workout for the arms and shoulders.

Typical process.

Locate the center of the galley bore.



Bore the galley end to 3/8" NPT size.



And then the worst part, tapping the hole.



I contemplated using an impact gun to drive the tap but since the tap is tapered there is a risk of cracking the case if you try to drive too much tap too fast. Cutting the taper is a time consuming back and forth affair of advancing the tap only about 90 degrees at a time and making sure the threads and the taper is cut before advancing another 90 degrees or so.

Finished the rear galley plugs.



And got three of the front end plugs in place.



Hope to finish up the other 5 tomorrow but those will require more complicated set ups on the mill due to the galleys being at an angle.