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Date:  4-4-2016
Number of Hours:  5.00
Manual Reference:  
Brief Description:  Rear Generator, Gold Oil System, Oil Pan, and Top

The objective today was to assemble and mount the rear generator. After getting started, I realized that the gold oil system had to be installed first, because one of its mounting bolts also served as a mounting point for the upper side of the generator system. So, the oil system components were located and the instructions read to be sure it was done correctly. The mounting surface on the rear case was given a thin coating of Permatex Ultra Gray RTV, then the gasket was pressed into the RTV to secure it in place. The top surface of the gasket was then coated with the RTV, then the gold oil block was bolted in position and torqued down.

The front halve of the generator pulley is replaced with the generator drive plate. To do this, the shaft nut is removed from the rear of the generator, the shaft is carefully removed, and the front half of the pulley replaced with the drive plate, the shaft reinstalled and the nut and washer replaced. The center hole through the drive plate needed to be reamed out about 0.009” before the shaft could be installed.

When I started to install the drive pins in the rear of the damper, I found the threaded holes in the damper were 5/16-18, while the threads on the drive pins were 3/8-16. At the time, I wasn’t sure which part was wrong. As I studied the problem later this evening, I determined that the drive pins were made from modified shoulder bolts. These had a shoulder diameter of ½”, a 3/8-16 threaded end, and a modified head.

After searching the McMaster-Carr catalog, I determined that the 3/8-16 thread was always used with the ½” diameter shoulder. This meant that the threaded holes in the Clark’s damper had to be upsized. So, tomorrow, I will make a drill and tap guide from ½” thick aluminum clamped to the rear face of the damper. This will allow me to up-drill and tap without removing the damper from the engine. The remainder of the assembly was fabricated and assembled without issue.

The oil pickup tube end was coated with Permatex Ultra Gray RTV,
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Generator Front Pully Half Removed & Drive Plate Installed.

Generator Front Pully Half Removed & Drive Plate Installed.

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Partially Assembled Rear Generator System & Gold Oil System.

Partially Assembled Rear Generator System & Gold Oil System.

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Top Plate and Starter Installed.

Top Plate and Starter Installed.

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