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1965 Kohler 6.5R22 to be Placed into Service


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  #1  
Old 06-23-2018, 06:53:57 PM
Vanman Vanman is offline
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Default 1965 Kohler 6.5R22 to be Placed into Service

I've had this set for a long time, and have a thread on it here already, but this is going to be different. This set will be installed under the floor of my Crown bus, and will provide auxiliary heat as well as power. This is the first time I actually have a specific end use in mind for one of my sets, so this thread will focus specifically on those preparations.

Here's the original thread:

https://www.smokstak.com/forum/showthread.php?t=133926

Today I started off briefly running it on ether, just to see that it still fires up, which it did instantly, and sounded great.

Then I ran a compression test:
#1 122 lbs
#2 124 lbs
#3 126 lbs
#4 121 lbs

The manual specifies 110 lbs compression, so I'm guessing that there's carbon build up. So I guess I should pull the head and have a look.

The manual states that the compression ratio is only 6.5 : 1, and I'm going to be running propane as primary fuel with premium gasoline as an emergency backup fuel, so I want to mill the head some to get the compression up and the fuel consumption down. When I get to that point the decision will have to be made: How much?

For now I loosely re-installed the plugs and wires.

I then drained the coolant, which was rusty brown. I had thought I had changed it at some point after getting it home, but I'm scatterbrained and evidently did not. Other than a few test runs I've never really used the set.

I drained the oil which was clean but with sludge. When I got it it had milky oil, and I thought I had all of the sludge rinsed out, but obviously not. I'm going to pull the oil base anyway to have a look see at the bearings, so everything down there will get thoroughly cleaned now.

Here are some photos in the current condition.
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  #2  
Old 06-23-2018, 11:15:04 PM
dkamp dkamp is offline
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Default Re: 1965 Kohler 6.5R22 to be placed into Service

Looks identical to mine, Keith!
I wouldn't mill the head... pull the head, and flush the block yes... rebuild the water pump, yes... scrub out the chambers and piston tops, yes, pull, wire brush, lap the valves, test each of the valve springs yes... but mill it... NO...
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Old 06-24-2018, 09:13:38 AM
Bent Trigger Bent Trigger is offline
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Default Re: 1965 Kohler 6.5R22 to be Placed into Service

Boy, does that look familiar! Good luck Keith, good you have a plan!
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Old 06-24-2018, 02:57:15 PM
dkamp dkamp is offline
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Default Re: 1965 Kohler 6.5R22 to be Placed into Service

BTW Keith-

There's another way to capture exhaust heat... AND silence the engine.

Make a muffler... vertically-oriented can. Wrap the conventional manifold in thermal fiber tape, hten plumb it to your exhaust can. make the incoming exhaust go down the center of the can, and stop about 6" from the bottom. Put 12" of water in the bottom of the can (submerge the exhaust by 6"). Use an exit tube that dips down into the can to limit water level to 6". Any excess water gets forced out the overflow, through a P-trap, so that exhaust cannot flow into the water path.

Now, this will create 6" W.C. backpressure on your exhaust, so your fuel mixture will lean accordingly (It'll drop your vacuum by that much at start-up... but once running, will not be noticeable).

Pipe from the top of the can, out to your exhaust exit.

As exhaust flows through the water, it will get very, very hot... very fast... so use an auxiliary water pump off the engine to push cool water INTO the can. Make the loop fairly short... to a heat exchanger (heat domestic water first, then the bus cabin baseboards and floor heat).

The advantage here, is that you won't have a concern with exhaust system overheat... the heat extraction system will cause the system to get very hot, but nothing will crack or burn up. A liquid cooled exhaust manifold MUST MUST MUST be water-jacketed and cooled at ALL TIMES... if not, it will warp, fracture internally, and leak coolant into exhaust... hence... become scrap iron.
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Old 06-24-2018, 10:59:15 PM
Vanman Vanman is offline
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Default Re: 1965 Kohler 6.5R22 to be Placed into Service

Interesting idea! Sort of a marine-ish exhaust, but capturing and recirculating the water. Still aways away from this stage though.

Not much to report today, just degreased the outside so it'll be nicer to work on. Covered up the mag to keep it dry, and avoided the generator and controller. Looks a lot better now.
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Old 06-25-2018, 08:05:36 PM
Grape Grape is offline
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Default Re: 1965 Kohler 6.5R22 to be Placed into Service

Don't have a lot to add but am concerned about carbon monoxide so using a water heating system seems the safest bet. I'll be following this to see how it goes for you. Good luck and have fun.
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Old 06-26-2018, 02:56:12 PM
Vanman Vanman is offline
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Default Re: 1965 Kohler 6.5R22 to be Placed into Service

Here's some of yesterday's progress. All of the fasteners came out with relative ease. None broken or stripped.

Not really a whole lot of carbon, but will clean it up and see about cc-ing the head. Maybe it's already been milled a bit. I also noticed it has remnants of gold instead of blue, so evidently not original to the set. Want to check it and the block for flatness.

The water pump seems to be in excellent condition, and I seem to recall the previous owner stating that it had been rebuilt. Looking through the weep hole the shaft looks pretty shiny still.

Factory gasoline / gaseous fuel carburetor, pretty cool. Might have to bush the throttle shaft but otherwise seems in good condition. I want to run propane with gasoline for backup.

Now I have to figure out how to get to the bottom end. I have a shop crane to lift the engine and generator off of the oil base, maybe just lay it on it's side with some blocks of wood.
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Old 06-26-2018, 06:37:03 PM
Vanman Vanman is offline
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Default Re: 1965 Kohler 6.5R22 to be Placed into Service

The cylinders don't look too bad. Can still see a wee bit of cross hatch, and don't feel any ridge with my finger, just some carbon.

You can see where it sat for a long time, and some moisture got in, just a little surface rust.

It runs so well, and has good, even compression that I can't see any reason to pull the pistons.

What do you think?
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Last edited by Vanman; 06-26-2018 at 09:58:40 PM.
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Old 06-26-2018, 07:08:42 PM
Bent Trigger Bent Trigger is offline
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Default Re: 1965 Kohler 6.5R22 to be Placed into Service

Quote:
Originally Posted by Vanman View Post
Factory gasoline / gaseous fuel carburetor, pretty cool. I want to run propane with gasoline for backup.

Now I have to figure out how to get to the bottom end. I have a shop crane to lift the engine and generator off of the oil base, maybe just lay it on it's side with some blocks of wood.
When you get the gaseous parts clean , can we get some pics and measurements? I've been wanting to make that part on the carb bottom.

I used 2x4s and they worked well. Once the gasket was loose I just rolled it onto the 2x4s, just be careful of the oil pump pick up. Or use a kid to do it for you! Just read the gennys still attached. Gonna need 3 kids!! You can be the supervisor! Chris
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Old 06-26-2018, 07:13:33 PM
Vanman Vanman is offline
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Default Re: 1965 Kohler 6.5R22 to be Placed into Service

Sure, no problem on photos and measurements on the carb parts.

I've removed all of the bolts between the engine and oil base except for a couple in the front. Then it occurred to me that they *might* have hidden a couple around the back end, requiring the removal of the generator. So I came inside to review the engine service manual, and this does appear to be the case per the diagrams. Dang it! I didn't want to remove the generator, but it clearly looks like there are a couple of bolts back there.

Last edited by Vanman; 06-26-2018 at 08:59:43 PM.
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