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Assembling a 547

Posted: Sat May 18, 2024 6:40 am
by Harlan Halsey
These days Carrera mechanics are thin on the ground. A friend called to ask about assembling an engine which his mechanic had had to abandon due to old age and illness. Starting with an assembled crank case and cylinder heads with valves, here's one way:
Rotate the flywheel to TDC. A and D gears to their assembly marks.
Torque on cylinder head
Drop in the long cam drive shaft, Aim pinion mark toward exhaust cam gear.
Install the cross shaft.
Drop in exhaust cam with timing marks aligned. Be very careful of the very thin end float shims. It won't go in because a lobe will try to depress a valve.
Rotate the crank via the flywheel simultaneously with the cam to a position where both lobes clear the valve stems and drop it in all the way.
Rotate the crank back to TDC and note that the timing marks are all now aligned.
Repeat with the intake cam. (The cam drive gears "hunt" they are all aligned only every-I forget, 19?-crank rotations.)
Now install mid-size valve stem caps and drag levers, using Doyle tool. Adjust valve clearance. If not within spec, 4 deg, change the valve stem caps as described in the Carrera Manual to get within spec. If you can't get within spec, move the alignment tooth. Each tooth gives 4 deg. Erase and re- do the alignment marks.

It is not possible to remove a Carrera head with the engine at TDC. Because the valve spring force will rotate the valve train and the alignment will be lost. However, Carrera mechanics know that the engine can be rotated to a position where the force on the cam lobes is minimal, and the train won't rotate when the head is pulled.
One year at the MHAR the Bruce Jennings Carrera Speedster, driven by Bob Garretson, needed a head gasket change. The owner borrowed my floor jack, and while we were out to dinner, pulled the engine and changed the head gasket. It took him about 4 hours, 5-9PM. Next day, Bob was a little faster in the Speedster than I was in my Carrera coupe. Those were the days....

Re: Assembling a 547

Posted: Sat May 18, 2024 1:05 pm
by Jacques Lefriant
32 revolutions

Re: Assembling a 547

Posted: Sun May 19, 2024 3:28 pm
by Jacques Lefriant
Hi Harlan
Peter Pohl has written a book on the subject. I have issues with some of the techniques just like with our mentor Jim W. it should be mandatory reading for the neophyte just to appreciate the task.
j

Re: Assembling a 547

Posted: Wed May 22, 2024 3:23 am
by Bill Sargent
+1 on reading the Phol book as well as the Heinrichs Carrera book.

Re: Assembling a 547

Posted: Wed May 29, 2024 11:07 pm
by Adam Wright
Harlan Halsey wrote: Sat May 18, 2024 6:40 am These days Carrera mechanics are thin on the ground.
Still miss Gerry.

Re: Assembling a 547

Posted: Thu May 30, 2024 9:01 am
by Jim Perrin
Adam
Those are wonderful photos of Gerry, thanks for posting them. Gerry was a very skilled mechanic on all kinds of engines, including the four cam engines. He was the one who rebuilt my 550 Spyder engine. You might be surprised to learn that Gerry was once fired from his job as a mechanic. Gerry told me the story of getting married to his wife Kay as a young man, renting an apartment in New York City, and very shortly after getting married going to work for the famous foreign car dealership J. S .Inskip. At the end of the third day, he was called in and fired as they said his work was not up to their expectations. Needless to say he was very surprised! Some years later he was talking to an individual who had been in management at Inskip at the same time ---- He then told Gerry the real reason was that he had been fired was that he had been seen talking to so-and-so someplace outside of work, and that person had helped form a union at another company!

Re: Assembling a 547

Posted: Fri May 31, 2024 9:04 pm
by Adam Wright
Jim Perrin wrote: Thu May 30, 2024 9:01 am Adam
Those are wonderful photos of Gerry, thanks for posting them. Gerry was a very skilled mechanic on all kinds of engines, including the four cam engines. He was the one who rebuilt my 550 Spyder engine. You might be surprised to learn that Gerry was once fired from his job as a mechanic. Gerry told me the story of getting married to his wife Kay as a young man, renting an apartment in New York City, and very shortly after getting married going to work for the famous foreign car dealership J. S .Inskip. At the end of the third day, he was called in and fired as they said his work was not up to their expectations. Needless to say he was very surprised! Some years later he was talking to an individual who had been in management at Inskip at the same time ---- He then told Gerry the real reason was that he had been fired was that he had been seen talking to so-and-so someplace outside of work, and that person had helped form a union at another company!
He was also fired from the dealer as the service manager. Ironically, it was a blessing because he went on to open his own shop which he had until he retired.
You won't see another Gerry anytime soon.

Re: Assembling a 547

Posted: Mon Jun 03, 2024 6:29 pm
by Dick Roth
Gerry was indeed a great guy and a true gentleman. I particularly appreciated the photograph of him with Herb Wetanson and his 904, with which he won the Saturday part (under 2 liters) of the Double 500 at Bridgehampton in 1965. I guess at this point it’s no secret that Herb quietly helped finance Gerry’s shop and called on his talents for many years.