[K3PZN-List] Generator Update

[Heath, Rob]

Thanks to everyone for the replies.  If we still have a spare around, that
would a nice source for parts if we need them.  If it is still in the
original box, maybe it has some service manuals as well.  For now, I think
tuning up the existing generator would be easier than swapping and trying to
get the other one running.  I found a number of things that need to be
worked on, but most of them are pretty minor.

The trickiest job is going to be lapping the valves.  I don't think we have
a problem with ware.  I think we probably just have a little rust and
pitting resulting from the valve sitting open for long periods of time.  We
could have an issue with the unleaded gas, but since the other cylinders are
in great shape I am thinking it might just be some pitting.  A lead
substitute is a good idea.  Hopefully we have not put enough hours on the
engine to do any harm yet.  Given the layout of the heads, a valve job
doesn't even look that difficult providing I can find a replacement head
gasket. Even without a valve job, cylinder 3 still has compression.  Since
the engine only runs at 1,800 rpm we may not need to worry about high
performance.

As far as the starter is concerned, I am steering clear of that project.
Fabricating a starter is beyond my skills.  If the Vo-Tech can do it, I will
leave it to them.  A traditional starter setup would require a new flywheel
with gears.  The existing flywheel is used for the magneto and as part of
the cooling system.  Its size and weight may also be required to maintain
steady rpms.  Swapping it out is probably not a simple task.  As a
compromise for now, I am thinking of trying a pinned shaft on the end of a
half-inch drill.  It is certainly not the ideal solution, but would be
better than cranking if it works.  There is some irony in using an electric
device to start the generator.  However, as far as I can tell the generator
is usually only started at the FTC and the field day site where small
generators are available to help start the big one.  This still leaves the
hand crank available if we need to use it.  With a good tune up and regular
exercise hand cranking may not be as difficult as is has been.

Rob