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Onan 2LK (experimental model) Has Come to Life!


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  #41  
Old 12-16-2017, 09:10:17 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Saturday Evening Update:

I did not have much time to spend on the LK. Time was spent Christmas shopping which I hate doing. However I did dedicate 30 minutes this evening and removed the flywheel to gain access to the timing cover. I plan to replace the timing cover seal as well as the governor seal. The first picture below shows the puller tool and the flywheel. You can see the OEM color peeking through on the flywheel fins. The second picture below shows a good leak-free timing cover seal and some oily dirty on the cover and block. Although the seal is not leaking, it is old and can fail upon usage. Now is the time to replace it. The third picture below shows the governor shaft, arm and seal. Looks to be leak-free, but I will replace the seal to ensure many more years of leak-free usage. The fourth picture below shows the bell end shaft bearing. It is an oldie and I cannot pick off the front seal cover. All my newer J series and RV gensets I was able to remove the bearing seal, clean out all the old bearing grease and re-grease the bearing for many more years of usage. If th ebearing showed rust or wear I would press off the old bearing and install a new bearing. The Nachi bearing cost about $10 each. Nachi was OEM for all my RV and J series gensets.

Well, the LK is ready for it's second bath which I plan to do mid next week. It is too cold now with temps in the 20's

That's all folks,
JohnnyC
New Jersey
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  #42  
Old 12-17-2017, 01:59:59 AM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Sunday Update: 12:52 am.

Tired all day Saturday, went to sleep early, woke up around mid-night and can't get back to sleep...... So, what did JohnnyC do? Went online and placed an order for gaskets with onanparts.com. The only parts that were not stocked were carburetor parts and rebuild kit. Other than that, he has what I need to move forward. A list can be seen below. Just an FYI you will notice that the description of the gaskets do not list them for LK models other than the oil base gasket. It appears most of the gaskets for the LK are shared with many of the CCK and other RV gensets.

I hope I caught mr. onanparts.com in time as he will be on vacation from December 21 to just after New Year.

JohnnyC
New Jersey
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  #43  
Old 12-17-2017, 03:14:09 AM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Nice when you can go to just one vendor and get everything you need without searching everywhere else for one part here and another part there.
Did you find the silver green paint formula? I'm looking for some or the 1958, 5CCK Ma Bell unit.
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Old 12-17-2017, 03:28:43 AM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Quote:
Originally Posted by JohnnyC View Post
Sunday Update: 12:52 am.


I hope I caught mr. onanparts.com in time as he will be on vacation from December 21 to just after New Year.

JohnnyC
New Jersey
Maybe. Could be. It's possible.......
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  #45  
Old 12-17-2017, 09:23:57 AM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

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Originally Posted by Motorhead View Post
Nice when you can go to just one vendor and get everything you need without searching everywhere else for one part here and another part there.
Did you find the silver green paint formula? I'm looking for some or the 1958, 5CCK Ma Bell unit.
No, not yet. That is an easy task and the automotive paint retailer guy is only less than 2 miles away. The reason for waiting is I wanted to do a full assessment on my LK. If there were any show stoppers and the paint was already mixed and bought, it would have been wasted since this shade of Onan green is different than the paint on all my 1980's-1990's Onans. When I get is matched and mixed I will document all the information and post it on this thread.

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New Jersey
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  #46  
Old 12-18-2017, 09:58:15 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Monday Update:

This evening I gave the body of the LK a bath to get rid of residual oil, grease and grim that was missed when I gave it a bath will all its tins, carburetor and fuel pump installed. I like to work clean instead of scraping off globs of crap when trying to work on the genset. Below are some before and after pictures.

My next step is to remove the oil base and see how much crap settled to the bottom over the last 58 years and to do a visual check inside the motor. Also I will rip off its head too. My objective is to find a left side high compression CCK head because ultimately I want to convert this LK to tri-fuel and it will need all the help it can get when running on natural gas.

That is all for tonight.

JohnnyC
New Jersey
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  #47  
Old 12-22-2017, 06:53:38 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Friday Update:

I needed Onan therapy big-time today especially after Christmas shopping yesterday. After work I immediately moved my LK from the garage and placed it on my work bench in my workshop where I can work on it and keep warm. I was so desperate for Onan therapy that I had to physically dead lift the LK from the floor to the table top and I believe a fully dressed LK weighs about 235 lbs. Since the flywheel and tins were already removed, it may weigh slightly over 200 lbs. Problem is I got a very bad lower back.

Anyway, once the LK was on the workbench I immediately remove the oil base from the motor. I expected heavy sledge, maybe metal shavings and hard chunks at the bottom of the oil base, but was surprised that all appeared to be normal. In the first picture below and on the left I show what it looked like after immediately removing the oil base. No goop or anything abnormal, just the residual that did not drain out. On the right hand side, I show what it looked like after spraying brakleen to remove the residual oil. I will totally strip the paint and do a good clean up of the oil base at a later date.

In the second picture below, I show what it looked like peeking into the guts of the motor. I did not clean nothing, Looks good! The connecting rod is the only aluminum part. All other parts are iron.

I removed the head to see what I would find. Well, the head is a low compression head as expect and seen in the third picture below on the left side. There is no abnormal accumulations of crap. I never removed the spark plug, but as seen in the picture (look closely) it is perfect. No indication of burning oil, lean or too rich. the plug tip is a perfect color. On the right side, I show a snapshot of the piston top and valves. Again, nothing abnormal is seen here. I quickly cleaned the piston top and it is a standard size piston. The cylinder bored had no ridge at the top of the bore after cleaning away the deposits. Unfortunately the hone marks are not visible, but the cylinder walls are fine and a previous compression test show great compression (in the middle of the chart).

The fourth picture below shows my LK as it looks now.

That's it for now. I have not been inside my house since the time I got home and I'm starving. Today's Onan therapy is a success and I feel better now.

JohnnyC
New Jersey
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  #48  
Old 12-22-2017, 08:28:40 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

More on Friday Update:

After going into the house from my workshop there was a box sent to me from Santa OnanParts.com. My parts arrived and PERFECT timing!!! What parts did I get? See the picture below, but basically it is all the common gaskets and a fuel pump rebuild kit for my LK. For the breakdown I show a list in one of my previous postings. I had explicit instructions from TJ at Onanparts.com not to touch the candy. It goes to the Boss, but most likely it will end up in the tummies of her grandkids this weekend. I'm sure they will be bouncing off the walls on a sugar high ... Also, TJ - Thanks for the little envelope too!

TJ - thanks , Merry Christmas and enjoy your vacation!!

JohnnyC
New Jersey
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  #49  
Old 12-23-2017, 12:49:44 AM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Update to my Update for Friday's Update:

I could not get enough Onan therapy so after dinner I went back to my little workshop and continued work on the LK now that I can move forward with new gaskets.

I started to strip off the original and el-cheapo after market paint from the main body of the generator. Tins will be done much later. In the picture below, it looks as if most of the paint has been removed. Believe me, there is a lot more to go before the metal is prepped properly for primer and paint. I have to remove every spec of the el-cheapo paint otherwise it may lift after I spray automotive paint. I must say that the person that did the after market paint job gets an "A" for coverage. Every nook and cranny was hit with the paint for excellent coverage, but since it was cheap and I assume rattle can spray paint it did not hold up well.

Below is a picture where I stopped at 11:15 pm this evening. Tomorrow is another day and lots more paint needs to be removed.

JohnnyC
New Jersey
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  #50  
Old 12-23-2017, 03:04:20 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Today I spent some time to remove paint from the other side of the LK which is the more difficult side due to all the nooks and crannies. I got to remove all the cheap rattle can spray paint before spraying real paint on the LK otherwise the new paint most likely will lift. I have maybe another 3 hours of work to do. It is a time consuming task, but since I got the LK on my work table in my workshop I don't mind spending the time since I got heat and tunes. Working in the garage floor where the LK was previously took it's toll and was cold.

Got to go do some Christmas chores and maybe if time permits I will be back in the workshop after 8 pm tonight until ??????

JohnnyC
New Jersey
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  #51  
Old 12-24-2017, 12:06:03 AM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Saturday Update:

I more or less finished the paint removal on the body of the LK (tins will be done much later). I reinstalled the oil base, new gasket and torqued to spec. Next, the timing cover was removed and maybe on Monday I will clean up the cover, install a new front seal and a new governor seal. Although the old seals did not appear to be leaking, they are old and they could leak at anytime, so since I'm there I may as well replace all gaskets and seal. The pictures below show where I left off tonight. The last picture shows how I kept my workshop work area nice and warm for most of the day while outside it rained from sun up to sun down with temps in the 40's .

JohnnyC
New Jersey
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  #52  
Old 12-24-2017, 04:36:14 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Sunday Update:

No work is planned for today since the big Christmas celebration starts tonight at 6 pm however I did receive a private message from a fellow Staker asking the following question that I wanted to promptly answer:

"Hi JohnnyC, I've been following along on your recent LK project, looks good.

Just curious, what are some of the methods/tools that you use for paint removal? especially in some of all of the nooks and crannies these gensets typically have.
"

I responded, but I really wanted to show pictures which can't be done in a private message and maybe others out here may be wondering what tools I use to remove paint. I attached several pictures below show the tools and brushes. A picture is worth a thousand words.

In the first picture below I show an assortment of wire brushes and a 4.5 electric angle grinder, Scotch Bright pads, and a chemical stripper. What is not shown is Brakleen and Acetone. Each brush serves its own purpose and I recommend buying them at those cheap stores such as Harbor Freight. You will pay pennies compared to Home Depot and Lowes. These brushes will get trashed very easily after using them.

In the second picture I show a set of Tube Brushes. I paid less than $4.00 and these are excellent for cleaning the cylinder head fins and recesses where other brushes won't reach.

The third picture shows an excellent example for the use of tube brushes. The deep recess in the oil base shown by the arrow in the left side picture contained some nasty crap and old paint. Trying to wipe with rags and Q-Tips won't work. On the right side I show the oil base recess after spending 20 seconds with a stiff tube brush. It would look better if I further cleaned it out using compressed air to remove the dust that resulted after scrubbing the recess with a tube brush.

As for chemical strippers, I try not to use them. I will only use a chemical stripper for really hard to reach areas where by softening the paint will make it easier to remove it.

After all paint is removed, a COMPLETE wipe down is done using Acetone and gone over once more with acetone just prior to prime and paint.

Okay, class dismissed. Have a Merry Christmas / Happy Holiday or whatever you may or may not celebrate.

JohnnyC
New Jersey
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  #53  
Old 12-24-2017, 04:46:24 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

I'll add to Johnny's stuff, Personal Protective Gear such as thick gloves when working with an angle grinder, A wire wheel is REAL FAST at removing SKIN, Safety Glasses and a dust mask.
I use Muriatic Acid to get rid of rust between the cylinder fins and other areas but ONLY, Outside, with thick rubber acid proof gloves, eye protection and I have a qualified respirator and a water hose handy.
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Old 12-24-2017, 05:33:00 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Quote:
Originally Posted by Motorhead View Post
I'll add to Johnny's stuff, Personal Protective Gear such as thick gloves when working with an angle grinder, A wire wheel is REAL FAST at removing SKIN, Safety Glasses and a dust mask.
I use Muriatic Acid to get rid of rust between the cylinder fins and other areas but ONLY, Outside, with thick rubber acid proof gloves, eye protection and I have a qualified respirator and a water hose handy.
Thanks for completing the list with the protective gear. Protective eye wear, Leather gloves is a must as well as a heavy leather jacket is a must when using the angle grinder. No lose clothing either. That grinder can be a nasty tool if it should slip or kick back at you. It will tear your skin apart and could rip your shirt off your body if you can't shut it down fast enough.

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Old 12-24-2017, 06:07:46 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

AMEN! I have lost some skin on my hands from being lazy and not wearing the leather gloves.
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Old 12-24-2017, 06:26:44 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

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AMEN! I have lost some skin on my hands from being lazy and not wearing the leather gloves.
Me too and I have a friend that was wearing a baggy T-shirt when the electric angle grinder's brush caught the shirt at the bottom with the aggressive brittle wire brush and took in the shirt all the way up to his chest. It took skin off his chest leaving blood before he was able to stop the grinder. He still has a scar 3 years later.

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Old 12-25-2017, 05:39:07 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Monday Update:

I spent a couple of hours this afternoon on the LK working on the timing cover. The old timing cover crank seal as well as the governor shaft seal was replace The cover was cleaned and old paint removed then installed back onto the LK using a new cover seal. I attached several pictures showing the removal of the old cover seal and pressing in a new seal using big sockets and a bench vise. All very simple to do.

JohnnyC
New Jersey
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Old 12-25-2017, 05:46:00 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

Some pictures with the timing cover reinstalled onto the 2 LK.

JohnnyC
New Jersey
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Old 12-25-2017, 07:47:22 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

You need a small bead blast cabinet with a good high volume air compressor Johnny.
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Old 12-25-2017, 09:33:08 PM
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Default Re: Onan 2LK (experimental model) Has Come to Life!

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You need a small bead blast cabinet with a good high volume air compressor Johnny.
It was on my Christmas list, but instead I got coal in the stocking

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