So.... The initial rebuild begins. With the displacer.
![:dremel:](https://madmodder.net/Smileys/default/smiley_dremel.gif)
I
really, don't like copper pipe for this purpose. Too heavy. Too much heat absorbtion/ conduction.
![](http://smileys.on-my-web.com/repository/Others/others-221.gif)
Lots of handy diameters and lenghths, of s/s exhaust available on Ebay. This is 42mm......
![](http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161004_112832728_zpsjgnt23iw.jpg)
Bored out, to lighten. Now, around 20 thou' wall thickness.......
![](http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161004_144937850_HDR_zpsw1xv0pug.jpg)
8mm thick, s/s offcut, friction turned, to slide in the displacer's bore.......
![](http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161012_132416255_zpsgzpzkayj.jpg)
Chopped the inside away, to give 1mm wall thickness......
![](http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161013_113747333_zpsd0zci2k1.jpg)
Drilled through boss. Silver soldered in, a 12mm long extension. Then drilled to spigot depth, and tapped M5.
Rough cut end cap, in background Awaiting friction turning........
![](http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161014_114309770_zpsvdzqmnzw.jpg)
Silver soldered in, both end caps. Cleaned up.
That looks better! Even though, it will not be seen........
![](http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161014_145939438_HDR_zpsk2ytcitg.jpg)
Next up.... Reducing the power cylinder bore. From 35mm to 29.5mm.
I used two more lengths of s/s exhaust pipe. They have very accurate and consistant, bores and o/d's.
A couple of thou' removed, allowed two to be sleevelocked together.
Topped to just below original bore size. Then bore opened out to 29.5mm.
Lots of time spent
oscillating, to achieve a decent finish, and remove the 1 thou' taper.......
![](http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161010_132521889_zpslxu8u8eu.jpg)
Looks ok, I think! The joint can
just be seen, at 10 and 4 o'clock positions. close to the bore's chamfer.......
![](http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161011_132855594_HDR_zpskre5fwlv.jpg)
Frankly..... I'm not impressed by the little end's arrangement.......
![](http://smileys.on-my-web.com/repository/Thinking/thinking-012.gif)
![](http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161011_132731320_HDR_zps8xhv4wvm.jpg)
There's only poverty, holding the big end in place........
![:bugeye:](https://madmodder.net/Smileys/default/confused0068.gif)
![](http://i110.photobucket.com/albums/n95/Dayjo/2015%20Onward/IMG_20161016_084520175_zps83vaunls.jpg)
Guess, we now need a new conrod!
![:(](https://madmodder.net/Smileys/default/sad.gif)
Thanks for looking in.....
![:thumbup:](https://madmodder.net/Smileys/default/happy0034.gif)
David.