Harley Davidson 2002 Fatboy

This is the aftermath of my 22RE rebuild. I had it redone at autospecengines.com and I shot the whole process for a tech article--now all I need is a magazine to run it in!

For those who care... Canon 5DII, ISO 800, 580EX flash, and a home made abetterbouncecard.com .

We placed the engine in the freezer overnight to chill the crankshaft and reduce its size to make the timing gear installation easier.

This is the aftermath of my 22RE rebuild. I had it redone at autospecengines.com and I shot the whole process for a tech article--now all I need is a magazine to run it in!

For those who care... Canon 5DII, ISO 800, 580EX flash, and a home made abetterbouncecard.com .

Harley Davidson 2002 Fatboy

This is the aftermath of my 22RE rebuild. I had it redone at autospecengines.com and I shot the whole process for a tech article--now all I need is a magazine to run it in!

For those who care... Canon 5DII, ISO 800, 580EX flash, and a home made abetterbouncecard.com .

Harley Davidson 2002 Fatboy

The casting flash on this particular oil drain back hole was so bad that it didn't go through. We ended up drilling it out and opening it up properly.

This is the aftermath of my 22RE rebuild. I had it redone at autospecengines.com and I shot the whole process for a tech article--now all I need is a magazine to run it in!

For those who care... Canon 5DII, ISO 800, 580EX flash, and a home made abetterbouncecard.com .

Note the little booger of flash right in the middle of the picture just waiting to fall off and lodge itself somewhere.

The engine is just out of the freezer and we are applying some anti-seize to aid in the installation of the crank gear

Note the frost on the engine case.

This is the aftermath of my 22RE rebuild. I had it redone at autospecengines.com and I shot the whole process for a tech article--now all I need is a magazine to run it in!

For those who care... Canon 5DII, ISO 800, 580EX flash, and a home made abetterbouncecard.com .

The gearbox on this bike had signifigant amounts of water inside. It is obvious that rust is forming, but what is more critical is not the splines but the colar between the splines and the bearing. It is a seal surface. We were able to polish it out, but if pitting was bad enough it would have to be replaced.

After the initial blasting the case is washed to remove remaining abrasive and then washed with an acid that pulls any remaining corrosion to the surface. Then the case is rinsed clean with water.

OK so the factory replacement O ring is too small and does not allow for proper crush during installation. Note the gap between the O ring and the casting.

This is the aftermath of my 22RE rebuild. I had it redone at autospecengines.com and I shot the whole process for a tech article--now all I need is a magazine to run it in!

For those who care... Canon 5DII, ISO 800, 580EX flash, and a home made abetterbouncecard.com .

Here is the case after the first blasting. It looks good in the pictures, but the surface is rough. We are 1/3rd the way through the aluminum restoration process.

I am going to let the paint set overnight before I clean up the intake/exhaust ports with acetone. That product is quickly becoming my favorite.

Cancer? cure it with acetone!

This is the lifter and pushrod boot area. Note the overall rough finish. The outer ring is very jagged; it must be smoothed out if the pushrod boot is expected to seal properly.

Ready to rock and roll.

This is the aftermath of my 22RE rebuild. I had it redone at autospecengines.com and I shot the whole process for a tech article--now all I need is a magazine to run it in!

For those who care... Canon 5DII, ISO 800, 580EX flash, and a home made abetterbouncecard.com .

We lucked out as our original bearings were in excellent shape and we were able to use them over which is nice because changing them out is difficult and time comsuming. We went ahead and checked everything just to be certain.

The corner of the rail had a semi cracked off chunk of aluminum hanging off it. We snapped it off just before taking this shot. It was about the size of a Pez candy. The corner was smoothed with the die grinder to eliminate any further crack developments.

All the back spots are corrosion and pits in the aluminum.

We fabbed up a valve guide installation tool to make things easier...

The pores have been closed and the surface polished by the bead blasting. All the previous corrosion is gone and the case is ready for its final wash and oil coating.

The tool is two parts... one is a driver and the other a depth stop. We used an old valve stem as the pilot on the driver as it is is the correct 7mm diameter. Note there is a small countersink on the driver where the pilot goes into the driver to clear the raised wiper surface on the guide itself.

Here is the back of the engine case which has significant corrosion.

Since we installed new guides and valves we had to have the valve seats touche with the stone at the machine shop. Then we lapped the new vales and seats together.

Rough oil drain back hole from the front of the case from the timing gear area.

Harley Davidson 2002 Fatboy

Harley Davidson 2002 Fatboy

This is the aftermath of my 22RE rebuild. I had it redone at autospecengines.com and I shot the whole process for a tech article--now all I need is a magazine to run it in!

For those who care... Canon 5DII, ISO 800, 580EX flash, and a home made abetterbouncecard.com .

This semi-open hole was supposed to be rectangular and dump directly into the oil pan. It cleaned up easily.

This is the aftermath of my 22RE rebuild. I had it redone at autospecengines.com and I shot the whole process for a tech article--now all I need is a magazine to run it in!

For those who care... Canon 5DII, ISO 800, 580EX flash, and a home made abetterbouncecard.com .

On this model the cylinders, heads, and rocker shafts are all held in place by the head bolts. The stack all slide on the long studs and all the parts must be ready to go as all the pieces go together at once.

We lubed everything up with some Lubriplate just before assembly.

Can you tell which studs were inserted post media blasting?

This is the aftermath of my 22RE rebuild. I had it redone at autospecengines.com and I shot the whole process for a tech article--now all I need is a magazine to run it in!

For those who care... Canon 5DII, ISO 800, 580EX flash, and a home made abetterbouncecard.com .

Just out of the blaster... nice and shinny now!

The factory set up was a piece of wire that held the screen on. It was a bit loose and kind of junky, so we used some thin washers and cotter pins to tighten everything up.

I tried putting the pistons in first, then connecting the rods. Yeah...no way. It's way easier the normal way. The tapered sleeves make installing new rings a snap.