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DW10 Pony Rebuild

DW10 Pony Rebuild

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Oldcarman
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After bringing life back to a pretty sad Bosch MJK magneto, I moved on to the Zenith carb, which was REALLY bad. I need to find some TU4 parts for sure. Then today, I pulled off the engine cover/manifold.

I texted my friend (owner of DW10) this photo of his engine. I said the classic line from Monty Python "it's only a flesh wound" immediately came to my mind.

Luckily we snagged a pony engine a few weeks back on Fleabay which hopefully will have enough good parts to make one running unit. This engine sat outside in Minnesota for a long long time and it certainly shows. Kroil is my friend......

I guess I'd rather see this rust mess than a broken connecting rod and scored crank, but I was certainly hoping for better....
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Tue, Jan 15, 2019 2:59 AM
dewets
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Funny thing is, it ran when parked....
Somerset West, Cape Town
South Africa
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Wed, Jan 16, 2019 9:02 PM
STEPHEN
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Reply to dewets:
Funny thing is, it ran when parked....



"Like a sewing machine" every one!
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Wed, Jan 16, 2019 10:10 PM
rax200
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Reply to STEPHEN:



"Like a sewing machine" every one!
Yep kept under cover ij a shed and well oiled, just needs a little tlc


Regards
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Thu, Jan 17, 2019 2:24 AM
restore49
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Reply to rax200:
Yep kept under cover ij a shed and well oiled, just needs a little tlc


Regards
Would that be a good candidate for Electrolysis - next day all would be clean and free. Bob
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Thu, Jan 17, 2019 4:32 AM
Mike Meyer
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Reply to restore49:
Would that be a good candidate for Electrolysis - next day all would be clean and free. Bob
Usually the advert says, "Was running when parked, won't take much to get it running" 😆😆 Ya right, why doesn't the seller offer to fix it and fire it up before you call round then....

Thanks for sharing the story Oldcarman, I like your sense of humor, "Only a flesh wound".......
Mike
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Thu, Jan 17, 2019 6:13 AM
Layne
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Reply to Mike Meyer:
Usually the advert says, "Was running when parked, won't take much to get it running" 😆😆 Ya right, why doesn't the seller offer to fix it and fire it up before you call round then....

Thanks for sharing the story Oldcarman, I like your sense of humor, "Only a flesh wound".......
Mike


I looked at a 2 cylinder John Deere one time that was purported to be "running". I found the engine to be stuck, like most old tractors sitting outside for decades. The seller insisted it would break free and start running if it were pulled. Of course he wasn't willing to attempt it, that would need to be done after I paid for it and took it home.
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Thu, Jan 17, 2019 7:17 AM
Oldcarman
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Reply to Layne:


I looked at a 2 cylinder John Deere one time that was purported to be "running". I found the engine to be stuck, like most old tractors sitting outside for decades. The seller insisted it would break free and start running if it were pulled. Of course he wasn't willing to attempt it, that would need to be done after I paid for it and took it home.
I've just sprayed it down with Kroil and will let that soak in for a while. I haven't gotten the second engine home yet, but with the two, I am pretty sure I'll be able to make one good running pony. I've resurrected some pretty bad antique car engines over the years, so I'm not all that discouraged. The "flesh wound will heal"...

What are the weak points of these engines? I wouldn't expect that they ever accumulate very many hours, but also probably suffer from neglect.
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Fri, Jan 18, 2019 8:37 AM
Ray54
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Reply to Oldcarman:
I've just sprayed it down with Kroil and will let that soak in for a while. I haven't gotten the second engine home yet, but with the two, I am pretty sure I'll be able to make one good running pony. I've resurrected some pretty bad antique car engines over the years, so I'm not all that discouraged. The "flesh wound will heal"...

What are the weak points of these engines? I wouldn't expect that they ever accumulate very many hours, but also probably suffer from neglect.
The weak point in my experience is the dowel used to set the trust bearing it likes to wallow its whole. Maybe more care in setting would help,old Joe was getting old and tired when he worked on mine. The trust bearing is loose on all 318 pony's on all my D6's.
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Fri, Jan 18, 2019 11:07 PM
STEPHEN
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Reply to Ray54:
The weak point in my experience is the dowel used to set the trust bearing it likes to wallow its whole. Maybe more care in setting would help,old Joe was getting old and tired when he worked on mine. The trust bearing is loose on all 318 pony's on all my D6's.
Bearing installation calls for the hole to be transferred through the block into the bearing and reamed. Not every mechanic has or had the tools and inclination to get a press fit, and even so the years have taken some life out of that system. It would not be a bad idea to ream over size a few thou and fit a custom dowel.
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Sat, Jan 19, 2019 12:38 AM
Oldcarman
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Reply to STEPHEN:
Bearing installation calls for the hole to be transferred through the block into the bearing and reamed. Not every mechanic has or had the tools and inclination to get a press fit, and even so the years have taken some life out of that system. It would not be a bad idea to ream over size a few thou and fit a custom dowel.
After a marathon 1000 mile round trip on Saturday, I have the second pony home. Now I need to make one good one for the DW10 out of the two.

I was pleased to find that this fleabay purchase did not have any huge defects- it turns over, the throttle shaft moves and there are many parts on it that I needed. I think that this one is from a D6 rather than a DW10, but parts seem to be the same for the most part.

The down side is that one bore seems to have some pretty serious scratches. That will need to be fixed. So- are the "semi finished" pistons in the parts books what others have purchased? I am inclined to just sleeve it back to standard rather than machining pistons.

I'm always curious about why engines "die". It looks like someone broke the aluminum intake manifold, tried to weld it and it didn't hold. My other engine has a good cast iron intake manifold so I'm good on that. I also found one head stud that was broken and that likely caused a coolant leak into that cylinder as that was the one with the excessive wear.

Has anyone rebuilt a D6 or DW10 pony recently? is there anything to really watch for? Grinding valve stems to set lash makes me feel like I'm working on another flathead V8 Ford.... But it works. The engine seems pretty simple.
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Mon, Apr 1, 2019 7:53 PM
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