Most engines that come here for a rebuild have been taken apart several times and various parts used to keep it alive back in the day. This engine looks untouched and pretty much as it left the factory.

Another view.

Well, with every good news there is a surprise. Mud wasps came in the exhaust port and have been nesting there for years.

This cylinder is rusty and the piston is stuck, naturally.

The clutch is fantastic. It’s a gooey mess but well preserved. Not a thing was missing or incorrect.

A good cleaning and reassembly is all that will be needed here.

The drive disc, drive chain and drive sprocket are all in excellent shape and came off with no problems.

The Dynastart was another pleasant surprise. everything is in excellent shape including the brushes. This engine did not have many miles on it.

Everything is in excellent shape including the brushes. This engine did not have many miles on it.

The engine block is now ready to be split.

The crankshaft is free spinning with no binding. It too has never been apart and is in good shape other than being very dirty.

With the crankshaft removed the seals are now visible. They are hard and brittle, the number one reason to rebuild the engine. Bearings and bearing races are all in excellent shape.

The engine block is clean and ready to prepare for reassembly.

The crankshaft is fitted before the final prep of the center crankshaft case. A good fit with no play and new seals installed.

The crankshaft halves are pressed and bolted together.

Now the right side case is ready for installation.

First half is complete.

The Connecting rod and roller bearing installation.

The last half of the crankshaft case is installed.

I used a sealer for added insurance and to keep the halves from leaking oil later on.

crankshaft assembly is complete.

another view of the completed lower end of the engine.

The transmission is in excellent shape. A lot of sludge buildup from the old heavy oil over the years was the only reason to take it apart.

All that it is needed is a good cleaning.

All of the gears and lay shafts are free from any signs of abuse. The shifting action of the transmission is now very smooth.

The transmission is mounted to the engine.

Like the transmission, all that it is needed for the clutch is a good cleaning.

Dynastart flywheel installed. All of the electrical is clean and serviceable.

The brushes and armature show little wear and should last a long time.

Side clutch cover installed. I use a clear RTV silicone without a gasket to seal the cover.

The original pistons did not survive and the cylinders had heavy rust so I replaced them with a good serviceable match set. The piston on the left is one of the originals and the piston on the right is the replacement after coatings.

The piston on the left is one of the originals and the piston on the right is the replacement after coatings.

The cylinders are cleaned, de-carbon, honed and painted ready to install.

The cylinder heads are cleaned and bead blasted; both are in great shape.

The pistons and the cylinders installed. Piston to wall clearance is maintained at .005 per the Excelsior manual. Keep the oil ratio at 16:1, I use synthetic Amsoil.

The finished product less carbs.