59XLH Part I, Cases Cracked, What Else Is New??? Nbr 214

A new Sportster engine rebuild series of videos kicks off. I just got done doing a 1958 XL, by chance the next engine is a 59XLH. Progress is made in leaps and bound. Cracked crankcases are welded and readied for eventual reassembly.

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Foreign and I use the term ever so loosely uh been a busy busy uh season for me uh just got done with two Motors uh I got another one I’m going to start here in a minute today uh you guys seem to like the video on the 58

And as it just so happens I got a 1959 I’m fixing to get going on so uh I think I’m gonna do the same kind of video I did on the 58 about the 59 uh anyway uh that’s what we’re gonna do so uh let’s get started on that there it is

Uh arrived from France believe it or not uh crate was split open uh the guts were kind of spilling out of the crate but uh fortunately it looks like it’s all there so uh we’ll get it uh uh well actually I’ve worked on it a little bit already the crankcase you can

See back there is halfway clean looking uh that’s been power washed and bead blasted uh I cleaned it up enough to find some cracks in it so uh the first thing I was the first thing I always do is well the case is up because you can’t build an engine without crankcases

When I look these over initially uh covered with you know 50 years worth of crud or whatever uh they looked perfect uh after I pressure wash and sandblasted them I found that the left one was uh perfect there’s no cracks on the left one nothing I got to weld on the right

One however there was a very fine type crack over here a very fine tie crack over here which I’ve since ground out and a very fine tight crack in through here and that also comes out on the inside one of the things that’s kind of worth looking at is this

This crack right here went through to the outside of the engine okay I ground the outside down I veed it out so I could get a well beat in there I didn’t do the inside yet but see this black there’s a little web that I haven’t ground through yet that’s maybe a

You know this web is maybe a 30 second of an inch thick and this black is oil that’s oozing out of that little crack I’m gonna have to grind this out because if I don’t when the tig Arc hits it it’s going to just explode into Agave soot

And it will make it impossible to weld it’ll probably explode into a Gaba soot anyway but I’m going to do my best to minimize that so you got a crack there we got a weld got a crack here we’re gonna weld same thing up here I gotta grind this out

So I could get to the bottom of it weld it up and then there’s very little clearance between the generator idler gear and this crankcase they’re gonna have to machine out or out or grind it out to get clearance again and then of course this cracked in here uh

I’m going to do that next I’m not going to show you the welding because I can’t Weld and run a camera at the same time and I don’t have a a filter so you’d actually be able to see anything so there’s really no point in

It uh let’s go look at it when it’s done the uh the other concern I have when welding is that as I put heat into these areas it’s going to want to expand this metal and as it expands that metal this year that the generator bolts to is going to

Want to move away and uh it’s going to make this surface not flat so I’ve cleaned up the can cover gonna Bolt the camp cover on preheat it all weld as much as I can on the outside then of course I’m going to have to take the can cover off to weld inside

And when I’m done I’m going to pull the alignment dials out one here and one here and put it on a Surface plate and lamp it all flat again so a bigger project than it looks like all right finished well job we’re going to take off these high spots

With the file until they’re close then we’ll put it over on the surface plate with some uh with a big sheet of sandpaper and take it all down flat in order to do that these alignment dials are going to have to come out so I suppose I may as well do that next

If a guy is lucky and I probably not sometimes you could just grab them with the vice grips and they’ll twist right out I was kind of hoping since I had all this heat uh saturated in there that it might have loosened them up loosen this one up anyway it doesn’t

Look like it did yeah broke loose but still awfully tight all right we’re going to drill these and pull them out that’s like testing a well job if I don’t break the whole thing off I want to be good Okay not going to run the tap all the way through I don’t want to break it off on there we’re just going to put it in a few threads for it thank you half a socket over the doll got a 10 32 nut and should come right out that’s one foreign three

All right we’re gonna the first operation I’m gonna do is to flatten this surface off again so let’s take off some of this okay over to the surface plate uh let’s do this paint this black figuratively speaking let’s see how much of that Sharpie comes off all right I’m gonna

Hang as much of the cam cover ceiling surfaces I can over the surface plate well up until this you know these lumps for the oil pump I could get that on they’re flat See kind of what I expected uh this part is making good contact this part not so much because I believe that the heat I put in here as it expanded the metal it pushed it away uh from the sailing surface and of course once it solidifies once it freezes that becomes a permanent

Distortion now there are some scratch marks here so it is beginning to make contact uh the long and short of it is I think I could safely lose three or four thousands off of this if need be and judging by the fact that it’s contacting

Over here I don’t think it’s going to be much uh but we will be able to get a flat surface on this and get a good seal on it anyway you’ve got the idea 15 minutes on the surface plate back and forth sharpie’s been removed all around so the surface is flat and

Smooth I’m very happy with that I probably took off I don’t know three thousandths of material made probably not even that much I’m not worried about it because uh the only effect that’s going to have is I can and play and of course I’ll be checking it when I put it together if

There’s not enough I can ride as a machine a little bit off of the shoulder on the bushings on the cam cover but I think it’s going to be fine so uh next I think I’m just going to use a Dremel tool and make this approximately round

Then of course it’s going to have to go through the milling machine because I don’t have anything that can get in here to flatten this by hand okay this is the bushing that was in there obviously you can’t use it over again uh but I’m just gonna

Round this out where the weld went inside there okay so I clamped down on a late bed uh this is just all uh by eyeball so uh we’re gonna turn around and uh hope for the best hopefully I won’t break nothing huh [Applause] [Applause] foreign [Applause] Okay I’m fixing to do the last thing I’m going to do today which is to put this bushing in uh I’ve marked where the ovalignment pin was uh not because I’m going to try to hit that spot exactly again but because I want to miss it completely and get a fresh new hole

This bushing is a thousandth of an inch bigger than the old bushing it’s a nice fit on the other gear uh it might close up when it gets knocked in we’re going to use some green Loctite on it uh because I don’t want to break this off

The ear is supported on these blocks of two by four so that when I go to knock it in this will be supported it won’t be flopping in the breeze uh walls are done everything is dressed out uh I showed you this on a milling machine I

Milled this out on the milling machine touched it up with the Dremel tool uh but anyway we’re going to knock this in with some green Loctite on it and uh hopefully it’ll go in the hole all right ready to knock it in nice yeah and as suspected it did close up a

Little bit as it so happens I have a 9 16th reamer uh it is 0.561 no it is 0.562 the safety gear is 0.561 so theoretically I’ll just remit it should be fine whether it lines up or not that’s another question well it didn’t take much if anything out of there

Uh but the gear fits perfect okay I’m done for today it’s been hot but back and forth to the dirty shop uh this Machining wise is ready to go I’m going to give one more sand place and clean it up while y’all weren’t looking I put a heating coil in

Stripped out thread over here uh really this case is in very good shape other than these cracks that it had the last thing I need to do to verify all these wells in this case repair over here is this uh Irene I replaced and ream this bushing to fit this gear I got

To make sure the cam cover fits with the alignment dials in position and make sure that this gear still spins freely because it is possible that with the welding replacement of this bushing it won’t line up with the pushing on the cam cover so let’s see if I got lucky

Okay because the gasket affects the end play of The Idler gear and the cam gears I put a gasket in place so let’s see what happens foreign I can’t really feel any on play but the gear was free and loosen there so this is good uh

Well as far as the work I did on it the welding the pushing uh the gear and the Remy and all that all that is good so uh of course we’re gonna check the cams once I get cam bearings in there uh but anyway uh this is done so with that I am

Out of here hey thanks for watching coffee cups and stickers links down below uh join me on patreon if you feel like it I will see you next time bye