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Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision


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  #41  
Old 07-30-2016, 12:00:30 PM
JohnnyC JohnnyC is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

This morning I spent some time cleaning the oil pan cover and base. It was caked with grease and dirt and that was AFTER a general gunking. I think it will clean up nice after the dishwasher finishes and I'm still alive.

Picture time!!!

Picture #1) This picture shows what's left of the grease and grime on the oil pans base and cover. This is actually clean compared to what it looked like before I gave the BFA a general gunking.

Picture #2) They say a kitchen dish washer is for plates, silverware, pot and pans. Well, I am washing an oil pan base pan and an oil pan cover so I guess these qualify for a dishwasher. Let's see how they look in about an hour after they are done.

Picture #3) I am going all out, no expense spared, on this cleaning. I am using the Hi Temp Wash, Sani Rinse, and the Heated Dry options.


If I never return to post a follow up on the dish washing cleaning, you can guess what happened....

JohnnyC
New Jersey
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  #42  
Old 07-30-2016, 12:51:43 PM
len k len k is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

Dishwasher??? When ever I put something steel there the high heat and humidity likes to rust it a bit.

I always use a coffee cup of gasoline and a tooth brush . I do it over a plastic or metal tray (restaurant sheet pan) nothing gets in ground. Been doing it that way since I was a kid. Just don't make sparks or use a gallon of gas. I do it outside on pavement , and most gas I have in pan is ~ a coffee cup at a time, limits the risk.
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  #43  
Old 07-30-2016, 12:59:05 PM
JohnnyC JohnnyC is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

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Originally Posted by len k View Post
Dishwasher??? When ever I put something steel there the high heat and humidity likes to rust it a bit.

I always use a coffee cup of gasoline and a tooth brush . I do it over a plastic or metal tray (restaurant sheet pan) nothing gets in ground. Been doing it that way since I was a kid. Just don't make sparks or use a gallon of gas. I do it outside on pavement , and most gas I have in pan is ~ a coffee cup at a time, limits the risk.
No worries here - The BFA block and pan base are aluminum. The steel pan cover is already rusted, but I got plans for that.
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  #44  
Old 07-30-2016, 03:06:34 PM
JohnnyC JohnnyC is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

Well, the dishes are done, and the Onan too.

Pictures explain the story the best, so look below.

Picture #1) As can be seen, the Onan is cleaned and sanitized as per the dishwater control panel. You should be able to eat off of it now.

Picture #2) No, I'm not going to cook it now on the stove top. It is just a place where I took a picture of the oil pan base after taking it out of the dishwasher. Nice and clean, but I need to remove old paint and especially the corrosion from years exposed to the salty Northwest winter roads that eat into the aluminum like butter.

Picture #3) I spent about 10 minutes removing corrosion from the external surfaces of the oil pan base. Getting into the nooks and crannies require time, but I can get it to look good with a mirror finish, but rough enough for epoxy primer and good quality automotive paint. Rattle can paints are forbidden in my shop.

That's all for today - got to get ready for a birthday party tonight.

JohnnyC
New Jersey
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  #45  
Old 07-30-2016, 03:13:04 PM
len k len k is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

Tell me about the green disk on the die grinder, never saw one of those. Does it have abbrasive fingers??

Lot of old stuff had lead paint, I'ld use a fan to pull the dust away.
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  #46  
Old 07-30-2016, 03:21:31 PM
JohnnyC JohnnyC is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

Quote:
Originally Posted by len k View Post
Tell me about the green disk on the die grinder, never saw one of those. Does it have abbrasive fingers??

Lot of old stuff had lead paint, I'ld use a fan to pull the dust away.
Len the green disk has abrasive fingers. They come in other colors too which denotes its coarseness. These are specifically used for aluminum and other soft metal surfaces for (in this case) removing gaskets without removing significant soft metal. It blew off the corrosion and old gaskets material like a leaf blower blowing a small pile of leaves.

As for lead paint, I am immuned to lead - I already have brain damage

JohnnyC
New Jersey
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  #47  
Old 07-30-2016, 03:26:51 PM
Power Power is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

WWWWW Washing with your dishes in machine!!!!!
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  #48  
Old 07-30-2016, 03:29:33 PM
len k len k is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

I'll have to try it , I've been using 2 inch wire wheel on die grinder for paint and rust.

For gaskets I just use puddy knife and razor blade, removes no metal.

I sanded a lot of cars doing body work, found out in the 80's they were still using lead paint.
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  #49  
Old 07-30-2016, 04:40:59 PM
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

A clean generator is a happy generator...

Bob
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  #50  
Old 07-31-2016, 09:06:14 AM
Tracy T Tracy T is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

I caught hell for putting a fairly new pair of tennis shoes in the dishwasher by themselves! Surprised you are alive to tell about onan parts in the dishwasher!
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  #51  
Old 07-31-2016, 10:53:46 AM
gchank gchank is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

Note to self-----

Don't drink or eat off of Johnny's dishes if any Onans are being
repaired/rebuilt as we dont know the mix of the dishwashers last load. Next time at least remove the silverware and dishes....
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  #52  
Old 07-31-2016, 12:29:29 PM
len k len k is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

Dishwasher did a surprisingly good job of getting it grease free for painting.
Would have run the dishes and silverware separate though.

Haven't heard from Johnny today .......maybe his other half saw what he washed......
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  #53  
Old 07-31-2016, 01:42:09 PM
JohnnyC JohnnyC is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

Quote:
Originally Posted by len k View Post
Dishwasher did a surprisingly good job of getting it grease free for painting.
Would have run the dishes and silverware separate though.

Haven't heard from Johnny today .......maybe his other half saw what he washed......
I'm still alive. I was out until early this morning at a birthday party so i slept in late then had to do weekly chores. I am currently eating lunch then off to Hopless Depot then playtime in the garage with the BFA.

JohnnyC
New Jersey
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  #54  
Old 07-31-2016, 07:39:59 PM
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

This afternoon I had some "quality time" with my BFA. I continued forward by preparing parts for prime, so I finished the oil pan base, re-rusted the oil pan cover as well as the flywheel, and removed the timing cover.

I punched out the crank seal on the timing cover without any issues and have a spare new seal from my 6.5NH project. They are the same crank seals. I attempted to remove the governor shaft and in doing so I lost the freaken little ball bearing that sits in the little hole in the timing cover. Luckily I have a spare ball from my T260 motor.

I ran into a problem when I attempted to remove the governor arm shaft. There are 2 Philips head screws that secure the fork to the shaft. I got one screw out and it was tough. The second screw would not budge and I stripped out the screw head. I had the EXACT same issue when I rebuilt my 6.5NH, but I was able to eventually get the freakin screws out without realizing that they may have been peened. As for the 4.0BFA, no way is the screw coming out.

Upon close examination of the screw, I can clearly see that the end of the screw was peened onto the governor shaft making it nearly impossible to remove and this may have been why I always had a hard time removing these screws. I attached 2 close ups of the p.i.t.a. screw where it was peened. Is this normal factory procedure? I don't remember reading about this in the past.

Tomorrow I will lightly grind the peened area and attempt to remove the screw. It I snap the screw in the governor shaft, I'm screwed.

JohnnyC
New Jersey
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Last edited by JohnnyC; 07-31-2016 at 08:00:36 PM.
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  #55  
Old 07-31-2016, 10:00:24 PM
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

I have removed screws like that on old carburetors. Some times when the screw head strips out, grind off the head of the screw and simply grind a slot in it and remove it from the "peened" side.
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Old 08-01-2016, 06:42:10 PM
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

Today I successfully removed the striped screw. To do so, I lightly ground the peened end and cut a slot in the head of the screw for a flat blade screw driver. The Philips head was too boogered up to save.

Lesson boys and girls - When removing the fork on the governor shaft, FIRST check to see if the end of the screw is peened. If so, you WILL have a fight on your hands unless you lightly grind down the peened end.

Picture time!

Picture #1) shows light grinding in the red circle. Screw was already backed partly out.

Picture #2) this pic shows the screw head after a slot was cut into it.

Mission completed

JohnnyC
New jersey
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  #57  
Old 08-01-2016, 06:48:39 PM
len k len k is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

This is the reason I never want to touch a throttle shaft. Easy to bend it too.
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  #58  
Old 08-02-2016, 09:09:59 PM
JohnnyC JohnnyC is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

Today was a day of slacking off and I only did a couple of things to 4.0 BFA. Mainly, I searched and found a spare screw which is used to hold down the governor shaft fork that I saved from an Onan T260G parts motor. I butchered one of the original screws on the BFA which I explained in detail in yesterday's post. Although a small screw may seem insignificant, I doubt many stores would have the proper size in stock.

Also, I pressed in a new crank shaft seal into the timing cover. I had a new spare from my 6.5NH project after accidently ordering 2. The seal is the same between the 6.5NH and 4.0 BFA (the originals have the same part number).

Since the timing cover is made of cast aluminum and is thin, it said to be prone to cracking if you hammer on the crank seal so it is advised to press out the old seal and press in the new seal. If you don't have a press, you can use a bench vice with the appropriate size sockets to do the job easily.

I attached 3 pictures below showing the process of using the bench vice and the finished job showing the new seal in place.

JohnnyC
New Jersey
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Last edited by JohnnyC; 08-03-2016 at 05:46:38 AM.
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  #59  
Old 08-04-2016, 09:46:57 PM
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

Today I spent an hour working on the badly rusted, but savable control box cover. The task was to remove as must rust as possible and assess the pits left in the metal from the rust. I will need to spent a few more minutes removing the remaining rust as seen in the pictures below.

Picture time!

Pictures #1 and #2) These two pictures show the rust and what's left of the paint after 33 years from salty winter Northeast.

Picture #3) Look close. 90% of the rust is blasted away and look at the pits left in the metal. If I simply prime and paint over what's seen, it will look hideous. A few more minutes of preparation and then I plan to fill the pits with filler. After sanded, primed and painted, it will look like new (I hope).

Picture #4) This is the under side of the cover. I removed 90% of the rust and is not nearly as bad as the outside of the cover. I plan to leave the wiring schematic decal in place and blend the new paint into the paint that surrounds the decal. If done right, 99% of people looking at the decal will never know (I will be the 1% that does know).

Not pictured but done today - I removed all the rust on the cast iron flywheel and got it ready for prime. Likewise, the oil pan cover underside was de-rusted and ready for prime. I plane to prime and paint as many parts together so primer and paint is not wasted.


JohnnyC
New Jersey
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Old 08-05-2016, 05:21:07 AM
Tracy T Tracy T is offline
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Default Re: Sacrificial Onan 4.0 BFA - A JohnnyC Executive Decision

I feel your pain with the rust issues, I have a 1995 k2500 & a 1992 f250 frames to start sandblasting on this evening. Gonna be a busy couple days for me.
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