Silver is so last month, so blue it is this time!
We used red hamerite on the exhaust plugs and those didn’t discolour until we welded something on it – so it seams heat resistance enough!
The hammered blue looks great out in the light.
Oil pump disassembled and cleaned. It all looks fine nothing really worn so no need to replace it.
The parts slot right into place, covered in assembly oil. This stuff is thicker than normal oil and kinda sticks to everything. Should help keep everything lubricated on the fist run.
The filter element has a few hardended clumps inside it but nothing major!
M52B28 crank shaft sitting in the M20 block – this end will need some kind of spacer for the oil seal.
Crank sits in the block like it was meant to be there – only other thing that need to be tested is the M20B20 130mm conrod with the M20B25 pistons in place to check clearances.
One more picture for good measure!
One question, how the h*** to do you the cam belt pulley off the crank? It seems to be wedge solid. The cam chain pulley came right off the M52 crank so I assume its the same with the M20 except I’ve got 20 years of gunk keeping it on!
Today we installed the fuel level sender in the fuel tank – sounds easy but it took most of the day! Stage 1 was to figure out the numbering system as the chart that came with the sender only when down to 180mm deep tanks. The Marlin tank is 160mm. Luckily it was quite an easy one to figure out – 160mm depth, 67mm pivot, 63mm radius.
Next on the list was to make the hole that the send goes in. It was all going well until the dremel (110v 20 odd year old model) finally giving in and died leave the rest of the cut out and clean up to me done by hand. Still turned out quite nicely:
There was a lot of mess in the tank, but luckily one of the vacuum cleaner attachments fits in the hole!
This only leaves figuring out how to attach the fuel hose to the tank and mounting the filter/pump!
It took 2.5 years to build the car and pass SVA (now IVA) and a lot longer to get to where it is now! To see the Sportster out on the road have a look at one of the videos here.
During 2008 we rebuilt the BMW engine from 2.5 to a 2.8 creating an M20B28 stroker engine. It uses the crankshaft from the later BMW M52B28 and the conrods from the M20B20. Not much more work is needed other than a clean up, slotting those bits together and a crank spacer. To read about the engine build click here (very picture heavy!)
In March 2009 it was painted, a full set of images is here.