REPAIRING SCORED CYLINDERS
If the engine has been run at any time without adequate lubrication, one or more of the cylinders may be found to have vertical scratches running up and down the cylinder walls. The depth of these will vary according to the amount of time the cylinder was without lubrication, and if the grooves are very deep the only remedy is to purchase a new member. Of course, if sufficient stock is available in the cylinder walls, the cylinders may be rebored and new pistons which are oversize, i.e., larger than standard, may be fitted. Where the scratches are not deep they may be ground out with a high speed emery wheel or lapped out if that type of machine is not available. Wrist pins have been known to come loose, especially when these are retained by set screws that are not properly locked, and as wrist-pins are usually of hardened steel it will be evident that the sharp edge of that member can act as a cutting tool and make a pronounced groove in the cylinder. Cylinder grinding is a job that requires skilled mechanics, but may be accomplished on any lathe fitted with an internal grinding attachment. While automobile engine cylinders usually have sufficient wall thickness to stand reboring, those of airplane engines seldom have sufficient metal to permit of enlarging the bore very much by a boring tool. A few thousandths of an inch may be ground out without danger, however. An airplane engine cylinder with deep grooves must be scrapped as a general rule.
Where the grooves in the cylinder are not deep or where it has warped enough so the rings do not bear equally at all parts of the cylinder bore, it is possible to obtain a fairly accurate degree of finish by a lapping process in which an old piston is coated with a mixture of fine emery and oil and is reciprocated up and down in the cylinder as well as turned at the same time. This may be easily done by using a dummy connecting rod having only a wrist pin end boss, and of such size at the other end so that it can be held in the chuck of a drill press. The cylinder casting is firmly clamped on the drill press table by suitable clamping blocks, and a wooden block is placed in the combustion chamber to provide a stop for the piston at its lower extreme position. The back gears are put in and the drill chuck is revolved slowly. All the while that the piston is turning the drill chuck should be raised up and down by the hand feed lever, as the best results are obtained when the lapping member is given a combination of rotary and reciprocating motion.
VALVE REMOVAL AND INSPECTION
One of the most important parts of the gasoline engine and one that requires frequent inspection and refitting to keep in condition, is the mushroom or poppet valve that controls the inlet and exhaust gas flow. In overhauling it is essential that these valves be removed from their seatings and examined carefully for various defects which will be enumerated at proper time. The problem that concerns us now is the best method of removing the valve. These are held against the seating in the cylinder by a coil spring which exerts its pressure on the cylinder casting at the upper end and against a suitable collar held by a key at the lower end of the valve stem. In order to remove the valve it is necessary to first compress the spring by raising the collar and pulling the retaining key out of the valve stem. Many forms of valve spring lifters have been designed to permit ready removal of the valves.
When the cylinder is of the valve in-the-head form, the method of valve removal will depend entirely upon the system of cylinder construction followed. In the Sturtevant cylinder design it is possible to remove the head from the cylinder castings and the valve springs may be easily compressed by any suitable means when the cylinder head is placed on the work bench where it can be easily worked on. The usual method is to place the head on a soft cloth with the valves bearing against the bench. The valve springs may then be easily pushed down with a simple forked lever and the valve stem key removed to release the valve spring collar. In the Curtiss OX-2 (see [Fig. 1821⁄2]) and Hall-Scott engines it is not possible to remove the valves without taking the cylinder off the crank-case, because the valve seats are machined directly in the cylinder head and the valve domes are cast integrally with the cylinder. This means that if the valves need grinding the cylinder must be removed from the engine base to provide access to the valve heads which are inside of that member, and which cannot be reached from the outside as is true of the L-cylinder construction. In the Curtiss VX engines, the valves are carried in detachable cages which may be removed when the valves need attention.
Fig. 1821⁄2.—Part Sectional View, Showing Valve Arrangement in Cylinder of Curtiss OX-2 Aviation Engine.