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Post by lincolntbird on Jan 19, 2013 6:46:58 GMT -4
Does anyone have any experience on rebuilding & or modifying the EK42. I will be sometime down the track looking at rebuilding one & possibly looking at giving it a little more get up & go. ;D Any ideas or hints would be appreciated, also help in locating rebuild parts.
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Post by sikari2015 on May 9, 2013 12:06:34 GMT -4
Hey, I'm new to the forum but have owned my Sherpa for a few years now. I've heard a rumor that the EK42 can be bored out for Brumby pistons. It's probably just that, rumor, but might be worth looking into it. The manual has all the measurements so a quick comparison should be easy. As for parts, Precision engineering is the only place I've seen selling parts for the EK42. You could also look at bolting on an AMR300 supercharger . That's one of my pipe dreams. Lol
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Post by lincolntbird on May 9, 2013 12:29:49 GMT -4
Welcome to the forum. It's always good to hear from other Sherpa owners.Thanks for the tip about the pistons, will have to check up on the specs. Will also check out Precision engineering.
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Post by lincolntbird on Jan 7, 2014 20:08:42 GMT -4
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Post by lincolntbird on Jan 9, 2014 11:17:43 GMT -4
Have now got the engine striped down & the pistons & rods measured up ;D. I will try & edit & post the video of the dismantling process soon. The piston measures approx...76mm dia, full skirt depth...58mm, 18mm floating wrist pin, centre of pin to top of piston...28mm, side skirt depth...44.8mm, top ring land to top of piston...15mm. Rod length...123.5mm.
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Post by justyfied on Jan 9, 2014 18:30:14 GMT -4
Have now got the engine striped down & the pistons & rods measured up ;D. I will try & edit & post the video of the dismantling process soon. The piston measures approx...76mm dia, full skirt depth...58mm, 18mm floating wrist pin, centre of pin to top of piston...28mm, side skirt depth...44.8mm, top ring land to top of piston...15mm. Rod length...123.5mm. Yaaah You got the engine torn down, But now there is questions! If you have a bore of only 76mm is it possible that this spare engine is in fact an EK23 + Bore 76mm X Stroke of 60mm You might be able to tell where the piston top stopped in the cylinder and just measure the bore in the empty block to verify the stroke. 9.6 mm is easier to see than the difference of 2mm on the bore. Great that you have FULL Floating 18mm piston pins. Looking more and more like the Justy is a good source of pistons ;D So could you take another look at my post on measuring the Justy pistons and verify the compression height?-- 28 is probably then the same as the Justy, the pin is the same .. ...
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Post by lincolntbird on Jan 10, 2014 9:45:41 GMT -4
Sorry my mistake , the piston diameter/ bore should read 78mm . Just checked the Justy measurements & "drum roll please" the compression height is the same at 28mm ;D .
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Post by justyfied on Jan 10, 2014 12:02:52 GMT -4
Sorry my mistake , the piston diameter/ bore should read 78mm . Just checked the Justy measurements & "drum roll please" the compression height is the same at 28mm ;D . YES, So it is looking like the Justy EF10 engine Short block (Not the head) is an EXACT copy of the earlier EK42 with 1 cylinder added! ;D Need some really good verifiable , cross math proved measurements on the conrod length. Easier to measure without a piston on it! need width of the rod big end as well as diameter with and without bearings. I will measure up my EF10 rods so we can compare notes. I know they are shorter than the EF12 rods. just want to make sure they are the same.
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Post by lincolntbird on Jan 12, 2014 11:20:21 GMT -4
Okay the Ek42 con-rods measure....approx 120mm centre to centre, con-rod width 21mm, big end dia. 42mm with bearing, 45mm with out bearing, piston pin dia 18mm.
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Post by justyfied on Jan 12, 2014 15:19:13 GMT -4
Okay the Ek42 con-rods measure....approx 120mm centre to centre, con-rod width 21mm, big end dia. 42mm with bearing, 45mm with out bearing, piston pin dia 18mm. Alright those are so close that they must be the same as what I have. So this means that if you cannot get pistons in Standard or even overbore sizes, That you will be able to get pistons from a Subaru Justy 1 liter EF10 engine that will fit. There are just 2 fly's in the ointment. The valve notch's do not match up perfectly and there may be a problem or difference in that the wrist pins are either press in or full floating. Both of these are pretty minor things that can be fixed. New Zealand Subaru Dealers would be the closest source for new parts.
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Post by justyfied on Jan 14, 2014 11:55:48 GMT -4
So I have another alternative, there is a motorcycle engine that is fairly common in wrecking yards now. The Honda V65 4 cylinder V4 engine. It came with nice pop up high compression pistons. Problem, depending on how much you had wanted to spend is that it comes in a stock bore of 79.5mm, .5 mm bigger than the formerly available factory oversize of 1mm overbore. The other problem is that the connecting rod that comes with it has a smaller big end size of 40mm. So instead of just getting the crank turned down 2mm with the same stroke, have them offset grind it 1mm to get a 2mm bigger stroke (More expense!) So with the increase in stroke and bore plus the pop up piston you with have a higher compression and a larger displacement engine that should easily make an extra 10 or 15 percent more power(OVER 40HP) with out getting into efficiency improvements like a tubular exhaust header and a reworked intake manifold. BUT, you know what they say: When you are looking for more power, there is no replacement for displacement. Here is an Ebay listing for a set of these rods and pistons; www.ebay.com/itm/121055029317?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649#ht_1054wt_896
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Post by lincolntbird on Jan 15, 2014 7:13:47 GMT -4
Sounds an interesting alternative . Any idea as to what the piston pin size might be The way things are looking I might have to go the Honda pistons. Unless justyfied you have access to EF10 pistons . I sent an email to one of the New Zealand Subaru dealers asking about the EF10 pistons but have had no reply in 2 days . Took a piston into the local engine re-conditioners today to see if they can match anything, he had a quick look whilst I was there with no luck, but he is going to check into it further. It seems there is an anomaly with the water pump description on the Internet spares listings, they show a belt driven water pump where as the Ek42 uses a water pump driven by one of the balance shafts. So before you buy double check the description with the seller.
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Post by justyfied on Jan 15, 2014 18:46:43 GMT -4
Sounds an interesting alternative . Any idea as to what the piston pin size might be 20mm The way things are looking I might have to go the Honda pistons. Unless justyfied you have access to EF10 pistons . Look below for part numbers.I sent an email to one of the New Zealand Subaru dealers asking about the EF10 pistons but have had no reply in 2 days . Maybe the reason that the dealers haven't gotten back to you is because they do not have access to a parts manual anymore! But we do ;D So the Subaru factory part numbers for OEM Justy EF10 pistons are: 12009 KA120 For Std bore up to 1976 12009 KA121 For Std bore after 1976 12009 KA330 For plus 0.5mm bore up to 1976 12009 KA331 For plus 0.5mm bore after 1976 12009 KA340 For plus 1.0mm bore up to 1976 12009 KA341 For plus 1.0mm bore after 1976 What I do not know is which years had the press on the con rod wrist pin (Gudgeon) and which had the full floating pin retained with c clips in the piston. I would guess that since the picture doesn't show them and knowing how Subaru is too cheap to draft up a new picture every time 1 little part changes .. .. then it would be prudent to bet that the 77 and newer has the preferred floating pin piston.
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Post by lincolntbird on Jan 17, 2014 6:56:35 GMT -4
Thanks justyfied for the EF10 piston part numbers, I will shoot off another email to N/Z with the part numbers & see if anything comes back. Will keep you posted.
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Post by lincolntbird on Feb 2, 2014 9:12:50 GMT -4
Gave the cylinders a quick hone out today & they have come up pretty good, looks like I could use standard pistons & rings if I want . Gave the head gasket surface a quick clean & ran the straight edge over it to check for warpage & it looks pretty good in that department. So now I need to get the head crack tested & checked for hardness, I did a quick hardness test myself & it seems okay, but I would like to get it confirmed. No news from New Zealand yet about Justy pistons, might have to send them a reminder.
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