KAL the Extended Journey.

Holy cow! Looks like a dog shaking the water off. Should be good all braces up.

Yeah, I have 2 Ideas in mind. Maybe a combo of the 2.

Worked a little on the engine today.

All cleaned up, replaced the top seal that was leaking.



Had to replace the inspection plate gasket, so I took that as a good time to take a peak.  All looked good inside.



Reinstalled, I had already done the upper head gasket and decarboned it.  Valves on that side are to spec and seal well.




Cleaned, decarboned, and checked valves on the lower side.  The valves are to spec as well on this side.  Little bit of oil residue on this side.  I have seen this on other engines as well for the lower cylinder.  



Heads back on and torqued to spec. Fan sat down and now planning to create a pull start, Not sure If I remember if there is room for that.  I need to inspect some pix.  Next I plan on flipping it over and checking the bottom seal. I forgot if it was ok or not.  I think I already replaced it. Sump was fine, so I hope not bust that one open.



I already put a kit on the Carb, so I just need clean up the intake.

Bottom seal looked leaky too so since I had it, I replaced it.  Engine is slowly coming back together.



Just need to finish cleaning up the intake to wrap up the engine.  Below is a pulley I snagged from the parts pile that I plan on using for a pull start.  Looks like a good candidate.



SO....

as you know, I scavenged the tires from Kal to Red when I refreshed Red.  I bought a new set of rear tires last week.  Just like what I had on Kal.  I liked them pretty well.  I "Thought" I was purchasing the same tires.  Nope.  I got the shorter ones.  The new ones are only 24 inch tall instead of 27 inch high.  That brings me to a new issue.  I could do some minor mods that would make for a good trail rig, especially for places like Haspin.  But the lower stance is going to take away from it's ability to go through deep mud.  Hmm....

Why not put the 24 inch tires on red and put the 27s back on kal?

I may do that. The 24s would be easier on the 820.

How in the world did you get that engine block so clean? Degreaser?

LOL, I doused it with WD-40 and Ammonia for about 10 minutes then pressure washed it with Mean Green.  HEHE...

Ah, nice!

Good thing I am changing out the rear tires between Kal and Red.  Putting Kal's back on.  I am missing my lock collar on Red.  Wheel could have fell off.  I guess it fell off last time I was riding it.  YIKES!  I'll get a new one later.

Well, got Kal's paws back on.



Gonna take a break a couple days.  Back is hurting a bit today.  That and it is pretty hot out.

Engine is back together, I have the parts needed to make the pull start.  I'll probably start that this weekend.  I also got some metal.  I have some ideas on some structural support for the frame.  I noticed post Haspin 2019, that the transaxle vented itself out the gear shifter.  Blew some oil out.  Need to figure out a venting solution.  I really do not want to drill and tap into the case if possible.  I may look into adding a vent to the fill plug.  I need to change it's oil as well.  Sure there are some flakes from the rust that was in it.  I'm certain I didn't get it all out.

Didn't share earlier, but the engine is ready for me to finish the tractor...



Did some studying, and determined the twist was between the engine and the hand brake.  So, I have determined that I can run a H like pattern over the center section of the frame to stiffen it up.  Also, not picture, I will reinforce the front foot brace/bracket.  That will help as well.

Idea:

I would caution you on only bracing the middle, as your now adding a stiff section to a otherwise flexy frame. I think youll have cracking issues at the start and ends of your brace section. I would brace from at least the transaxle mounts to the coil spring mounts as thats whats carrying most of the load. I had a issue on my old toyota wheeling truck, the frame cracked and I welded a patch over it, then it cracked beside the patch, so I welded up the crack and added a long patch, and then it cracked beside it, so I ended up cutting a 2 foot long patch that was a super long v to try to allow it to flex and not have a sharp flat line to start another crack. that worked great and held up for a couple years until I sold it. even the stiffest frames will flex, you just have to account for it and try to make the loaded sections twist evenly so it doesnt do all its flex in the same spot and start a crack

I thought about that, the brackets for the transaxle are a kind of brace themself.  I plan on overlapping those sections in the back.  (green line passes those nuts in the back)



So as far as the transaxle part goes, it should be good.  If I have enough metal, I will go all the way back.

Kinda off topic but that's a neat setup with the disc brake on the transmission. Is it factory or did you make it?

Its factory.   Here are the brake pads..

That's awesome!

Did some work today.

Chopped off the handle to the hand brake and reconfigured to where it can be attached and removed due to the metal I am going to weld along the top.







Right side flatstock attached.  After the left side is attached, I will weld in some cross braces.

In the mean time, I have gone back and fixed some SUCKY welds.

Sucky weld....



Much Better!!

Refresh progress tracker..

• oil change, it had 2x capacity.  Lots of gas in the block even though I have a shutoff
  
• probably needs a carb kit
  
• valve job
  
• new head gaskets
  
• upgrade tail lights?
  
• if $$ is ok, maybe new fronts.  Put original tires back on!
  
• Not sure I like the frontiers on the rear. Put original tires back on!
  
• Air filter, one on it was robbed.
  
• possibly a new exhaust.
  
• Frame strengthening.
  
• Clean up old welds.
  

Forgot to post this yesterday.

Still coming together!

Engine is sitting back on frame. Not bolted yet.

Lookin good! Those braces stiffened it up alot

We'll see how it goes.  I have most of it together minus the hood.  Engine is all bolted up.  Trying to figure a better way to run dual throttle.  I'll probably end up with the way I was doing things.  We'll see.

Little sneak peak...

looking really good, love the attention to detail