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Help !!

 
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Old 05-06-2018, 10:03 AM
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Help !!

Just come back from road testing my F1, as I pulled in to my drive noticed steam coming from the bonnet. Switched off immediately and opened the bonnet (hood). The attached pic is what has happened. I have not had time to investigate at the moment...BUT essentially the generator and mounting has come loose and gone forward. The propeller fan has gone through the radiator fins. As yet I do not know if the bolts have sheared or what. Has anybody experienced anything like this. Advice needed please.
 
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Old 05-06-2018, 11:24 AM
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WOW!

Appears to me that bolts are missing. Sheared maybe?
On second thought it looks like the generator bracket is broken.
 

Last edited by Mixer man; 05-06-2018 at 11:26 AM. Reason: Second thought
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Old 05-06-2018, 11:29 AM
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I'd guess the stud for the bracket pulled out of the manifold. It appears to be an aluminum manifold?
 
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Old 05-06-2018, 11:49 AM
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It appears to be a around a $400.00 bill .
 
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Old 05-06-2018, 11:57 AM
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Old 05-06-2018, 02:01 PM
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Originally Posted by Mixer man View Post
Thanks to all for your responses. I have let it all cool down, and drowned my sorrows down my local pub for the afternoon. Tomorrow morning I will remove the radiator and generator and see what I can see. I think I might need further help with this one. When I get my facts together I will report back.
 
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Old 05-06-2018, 02:11 PM
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Originally Posted by firstrider View Post
It appears to be a around a $400.00 bill .
Sorry about that. It sure can dampen your spirits!

It might be a few Quid more for a radiator in England.
 
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Old 05-06-2018, 04:20 PM
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I agree with Ross. I can clearly see the cast boss that the generator stud would thread into, but there is no stud showing in the gap between the manifold and generator bracket. Either your stud came loose and backed completely out or it tore the threads out of the aluminum manifold. Looks like you’ll need to repair (heli-coil) the threads in the manifold and replace the stud and radiator. Rough day, brother!
 
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Old 05-07-2018, 01:40 AM
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Hello again, going to strip it out after breakfast this morning and take a look. So it looks to be an aluminium casting, and it should have steel studs threaded in to it ?.
 
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Old 05-07-2018, 03:07 AM
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On some aftermarket aluminum castings, the manufacturer will install a stainless steel threaded insert in all the threaded holes as the part is manufactured to increase the strength and longevity of the threads. I would suspect that they did not in this case because of the size of the threaded hole. That doesn't mean that you can’t do it yourself, though. And given the amount of wreckage you're looking to have to replace, a Helicoil kit to help prevent a recurrence would be a wise investment.
 
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Old 05-07-2018, 06:14 AM
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Originally Posted by BlueOvalRage View Post
On some aftermarket aluminum castings, the manufacturer will install a stainless steel threaded insert in all the threaded holes as the part is manufactured to increase the strength and longevity of the threads. I would suspect that they did not in this case because of the size of the threaded hole. That doesn't mean that you can do it yourself, though. And given the amount of wreckage you're looking to have to replace, a Helicoil kit to help prevent a recurrence would be a wise investment.
OK ...update. I have taken the radiator out, ready for repair. This morning I walked back up our road about a half mile to where I remembered hearing a bang yesterday. Laying in the road I found what I believe to be the sheared stud. There does not seem to be any further damage to the generator or fan mounting. Is this stud available on the market ?...stainless steel would be good as suggested. Or perhaps I will have to get one made. Does anyone
know the length of the stud, and the diameter and threads etc please.It does seem incredible that the generator and the fan are both held by just one bolt. Is there a modification available to strengthen up this ?. Or perhaps I have been just unlucky. Tomorrow I will hunt around for a radiator shop and see if the rad is salvageable.


Broken end of stud ?


Also note the nut on the generator bracket will not pull up because it fouls the rear of the casing. It will not turn the other way because the bolt is to long to get in. A shorter bolt may work (if it is long enough).
 
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Old 05-07-2018, 06:30 AM
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I now see that I misread your question - the stud itself should be steel and you did in fact find the remains of it. The nut and square washer are distinctive. I was referring to the threads themselves in the intake manifold being a stainless steel insert. I don’t believe that I would use a stainless stud in that application. Stainless bolts and studs can tend to gall and smear their threads. I’d replace it with a new high quality grade 5 or grade 8 plain steel stud. Unfortunately, the condition of that hole and it’s location may force you to take the intake manifold off of the engine to get the rest of the broken stud out. I have a bad feeling that the first couple threads are deformed enough that it will put up quite a fight. It may need to be drilled out.

That poor radiator is going to have to be recored. I’m not sure what you have available as far as radiator shops go over there, but in the US, a recore job costs about as much as a brand new radiator. The all aluminum units are quite a bit less expensive, but they kinda look funny attached to a traditional flatty in my opinion.
 
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Old 05-07-2018, 08:56 AM
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I had that exact thing happen 20 some years ago on my first F-1. The intakes generator mounting surface was cracked and finally broke away causing the bolt to snap and result in the same damage you have,
If you re-use that manifold, be very sure the bolt and threads are sound and the mounting surface is good.
A fan out of balance can also fatigue the bolt with the same result.
 
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Old 05-07-2018, 09:17 AM
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Sorry to see this happened to you...but look on the bright side.....it could have happened 50 miles from your house instead of in your driveway. Could have happened in a much worse place.
 
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Old 05-07-2018, 09:48 AM
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Originally Posted by tinman52 View Post
I had that exact thing happen 20 some years ago on my first F-1. The intakes generator mounting surface was cracked and finally broke away causing the bolt to snap and result in the same damage you have,
If you re-use that manifold, be very sure the bolt and threads are sound and the mounting surface is good.
A fan out of balance can also fatigue the bolt with the same result.
The fan being out of balance has occured to me. Thing is how can I check that ?. I wonder if I would be better off finding a steel inlet manifold. Of course though....probably a bit thin on the ground over here.
 

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