Bolens Diablo Rouge and Hus Ski Discussion Forums

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Made a few more pieces to the puzzle. Rebuilt the engine bolt brackets from stainless. Little bit each day.

I like the idea you have about making the motor mounts out of bar stock with studs rather than trying to wrestle your arm under the chassis to tighten a nut or a bolt. When I did a 200, I did just the opposite and put the nuts downward. It worked really well.

Thank you for sharing all your cool ideas Robert!

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Got all the parts sandblasted which took a couple of days to do.

Always like to do projects with my father. He went to college to learn paint and auto body way back when, so he said he would help with the paint.
Everything is in primer. There is some rust pitting that needs to be smoothed out before the final paint.

Bruce mentioned that he's come across several cranks that have slipped becoming untrue, and if I'm going after more horsepower this might be a problem.

Wondering if it might be an unbalanced clutch causing the crank slippage I pulled the clutch off and made a bolt to hold it while being spun in a crank balancer to check balance.

It showed the clutch to be very balanced.

Diving into it a little deeper the crank and piston looked to be run very little.

Checked the crank for straightness and it was within 1.5 thousandths which is in the zone.

The next step was to take the crank apart for inspection.

After the crank was apart I noticed one of the connecting rod thrust washers showed major wear which means something's crooked.

In the search to find out whats crooked I had to check the cases where the cylinder mounts to see if it was parallel to the crank.

I did this by making a round bar that fits into the crank bearing holes and then measuring both sides of the cases.

In the end the measurement was the same which means that surface is parallel to the crank.

I'm thinking the base on the cylinder was milled crooked. I haven't checked it just yet.

On the connecting rod I filed off extra metal then sanded it to remove weight and make it stronger. Cracks will most likely start where there is an imperfection like the bumps left behind after casting, so if you sand it down flat its harder for a crack to start.

In the end I removed 15 grams.