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Cylinder block modification.

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George

02-15-2003 09:27:59




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Two years ago I purchsed what I was told to be a TEA-20-80. It is a 6 Volt, 1951, Ser. # 190027. I have a cracked cylinder block (I think I cooked it, due to a faulty thermostat,,there is no temperature indication) anyhow I'm now in the process of replacing the block.
On disassembly I found the cylinder sleeves measured 85mm, assumed I had a 20-85 and located a replacement block for a TEA 20-85. I received the block and found the block to be identical except for the starter pilot hole. The replacement block starter hole was approximately 3.5 inches in dia. not the approx. 3 inches required to fit my starter.
I then located yet another block , this one with the correct size pilot hole for my starter, however this block has 80mm sleeves installed. On discovery I found the 85mm sleeves will fit the 80mm block, with some minor machineing of the block at the crankcase end.
My plan is to proceed with this modification and assembly using the 85mm sleeves in the 80mm block. This seems almost to simple to be true.
Is this a common rebuild? Am I headed down the wrong road? Please help me out here experts.
George

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Jim W

02-23-2003 14:00:54




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 Re: Cylinder block modification. in reply to George, 02-15-2003 09:27:59  
George,
At around serial number 172000, the bore size was increased from 80mm to 85 mm. At serial #200000, the electrics were changed to 12 volts. The 12v starter needed the bigger hole.
So folks may assume 6v = 20-80, which is true most of the time, but not in your case.
The 85 mm sleeves should fit alright. Not only that, but if you want you can get 86mm, 87 mm, 87.2 mm, or 87.5 mm sets of sleeves and pistons meant for a Triumph TR4, and they will fit.
While you're at it, the main and big end bearings from the Triumph will fit too, and I think you will save a few $ over getting them through MF. British Parts Northwest has about the best prices on these parts and they are great to deal with.
Regards,
Jim W
PS Figure 8 gaskets too.

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Kishore ZAR

02-18-2003 22:08:40




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 Re: Cylinder block modification. in reply to George, 02-15-2003 09:27:59  
George I was just wondering if it may be possible to have the machinist build up or weld a bbush around the starter to increase its diameter so that it could fit the block ?



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George ONT Canada

02-20-2003 10:20:29




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 Re: Re: Cylinder block modification. in reply to Kishore ZAR, 02-18-2003 22:08:40  
Yes, a bushing would make the block usable. However, the block cost $750.00 Cdn and was returnable at no additional charge. The block I used cost considerably less, even with the machining. The motor is back together now. I'll keep you posted.



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glen Ontario

02-16-2003 04:57:18




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 Re: Cylinder block modification. in reply to George, 02-15-2003 09:27:59  
George I faced the same problem my block was cracked from over heat , I had my hands on a replacement block from a scrap yard it was marked with yellow pen 20 85 when I got it home , Crap it was a 80 mm block I asked a machinest about converting it to 85 mm he did not reconmend it . I ended up fixing my old block it was cracked in 7 places .Where is your block cracked ?



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George

02-17-2003 03:00:23




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 Re: Re: Cylinder block modification. in reply to glen Ontario, 02-16-2003 04:57:18  
The block is cracked at the base of the cooling cavity, full length including the piers and bridge,on the carburator side. This is the area where any residue settles/collects in the cooling system. The crack started in the center then propagated in both directions.
I do consider the crack to be repairable, however to retain a respectable appearance, it should be repaired using the fusion process, expensive with no guarentee it will acually work. The original block is probably made from recycled scrap iron with many possible impurities.

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glen Ontario

02-17-2003 13:55:47




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 Re: Re: Re: Cylinder block modification. in reply to George, 02-17-2003 03:00:23  
Sounds like finding a good replacement block is the way to go .here in Ontario (Canada ) there not too hard to find .



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