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Onan Generators Restoring, operating and maintaining vintage Onan generators.

Onan Generators

Franken Genny


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  #71  
Old 12-06-2018, 05:36:01 PM
Newoldstock Newoldstock is offline
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Default Re: Franken Genny

A hitch has come up.
Two of the four bolts in the end bell are broken.
I drilled them and tapped one.
I found I had not completely drilled out the hole and tried to take it down a little deeper and I broke a drill bit off in the casting.
I do have about 3/8 of an inch of usable thread in that hole.
I will have to trim that bolt I guess and be very careful.

Now I need a 13/64 drill bit to do the other broken bolt and hope I do not have the same problem again.
I had hoped the get the final assembly done to night.
I need fresh eyes on this in the morning.

Ya that's not coming out.
Cobalt bit not a plated one a real hard sucker and its stuck good.

Talked to a man about an engine.
He's got GX240 Honda and its mine for 100 dollars.
He says its low hours, might need a valve job off a generator.
Also comes with all the Generator bits attached for free!
Maybe the fuel tank is of use?

Now into the money part of this build where I need to buy stuff like a head and a case cover.
Need to spend money at the machine shop to match crank to the head ( if possible... still room for more surprises )
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  #72  
Old 12-06-2018, 08:41:30 PM
AngrySailor AngrySailor is offline
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Default Re: Franken Genny

Do you have access to an EDM? Also you might have some luck with a GOOD carbide burr with lots of coolant to cut that drill out of there...
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  #73  
Old 12-06-2018, 10:34:46 PM
Zephyr7 Zephyr7 is online now
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Default Re: Franken Genny

Angrysailor is onto something. A solid carbide burr with lube and a VERY careful feed pressure might be able to eat out that broken bit. I’d do it on a mill with a continuos lube pump running to get the swarf out of the hole. It’ll be slow going, but should work. Be careful though, solid carbide tooling is really brittle and easy to “crunch” if you feed to hard/fast.

If you try this and the solid carbide tool get stuck, stick a steel punch down in the hole and wack it with a hammer to shatter the carbide tool to get it out.

I have broken many bits and taps off in things. I suspect angrysailor has too, which may be what made him angry

Bill
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  #74  
Old 12-07-2018, 05:44:32 AM
AngrySailor AngrySailor is offline
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Default Re: Franken Genny

“I have broken many bits and taps off in things. I suspect angrysailor has too, which may be what made him angry

Bill”

Just one more reason to be “angry at the world”
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  #75  
Old 12-07-2018, 09:39:07 AM
Newoldstock Newoldstock is offline
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Default Re: Franken Genny

I don't have access to anything fancier than a drill press.
I have given this a lot of thought.

I am going to buy one of those thread repair kits.
https://www.youtube.com/watch?v=B3WxsZxLqi0
And not use the release agent on the threads of a stud.
I once made the mistake of using this product on a cast iron end bell I clean with some Anaerobic thread locker primer .
It was just luck I got that bolt out.
If I follow the same process without the release agent I will never get the stud out.
In this case the stud will just be some ready rod or bolt cut to length.

One stud three bolts should be fine it will just look funny

If this develops a problem in the future I could rotate the whole end bell assembly and make 4 new holes.
Then it s just a case of rotating the brush rigging back to the neutral position for the DC brushes.
That's a lot of work though.
Everything is a lot of work when things go wrong.

But I am not angry.
I have hearing loss and tend to speak very loud.
I also wave my hands when I talk.
And I am a close talker ,on account of having a hard time hearing
It just makes me look Angry ( Or European ) when I speak......
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  #76  
Old 12-07-2018, 01:16:21 PM
Zephyr7 Zephyr7 is online now
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Default Re: Franken Genny

You can do much with a drill press. I have a drillpress and a crossvise (like an X Y table). I can do basic milling on it. Works ok for plastic and wood, charters on metal unless I go super slow with very light passes.

Anyway, try a burr in the drill press. Use a VERY light downward pressure, no force, just enough to overcome the return spring force in the spindle. Don’t move side to side, vertical only. Too much force or side to side motion and you’ll crunch the solid carbide burr. It will be slow going, but you can probably get the stuck bit out that way. Put some lube on the bit, and flush the hole periodically to get swarf out.

I’ve drilled chrome vanadium ball bearings before using solid carbide drill bits (no other bits can even scratch the super hard ball bearings). I grind a little flat spot first for the bit to get started. It’s slow, but it works. I’ve crunched the occasional bit too.

Bill
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  #77  
Old 12-07-2018, 05:32:11 PM
Newoldstock Newoldstock is offline
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Default Re: Franken Genny

I don't know Bill.
If I screw this up further I am going to have to start making significant modifications.

I am cutting my losses and going to stud the whole generator frame so it looks like it was made that way with some ready rod or something.

I know I have enough material in the bad hole to torque up a 1/4 inch ready rod.
Did I mention that part? These are only 1/4 inch

Now its Tatra time ( that's Miller time in Poland )
I ain't doing anymore today.
Just cooking supper and doing my dishes ect.
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