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Old 09-09-2013, 08:04 PM   #1
picinisco OP
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Taking apart a seized cylinder.

As part of the build that I am doing, I have a 75/5 with a seized cylinder. I need to get the piston out of the cylinder or at least get the cylinder off the engine.

I have tried atf, brake fluid, muriatic acid, acetone/ATF mix, a puller, and heating the shit out of the jug by dangling it over a camping stove.

Nothing will budge. I feel that I need to bust a hole through the piston to try and disengage it from the con rod.

Any advice short of junking the engine.
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Old 09-09-2013, 08:19 PM   #2
Kai Ju
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This might work

Find yourself a piece of at least 1/4 steel roughly the same size as the headgasket.
Drill five holes, four for the studs and one in the center for the biggest fine thread, grade 8 or better, bolt you can find.
Place another piece of steel, smaller than the bore, on the piston. Bolt your newly made pusher to the studs and screw down on the center bolt, against the steel plate.
Keep tension on the bolt while you soak it again with a product called Break- Free (http://www.break-free.com/?location=/products/index.asp)
Apply heat if necessary, add pressure with the bolt and lightly tap it after turning it.

Good luck and let us know if it works so I can take credit. (If it doesn't don't blame me)
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Old 09-09-2013, 09:05 PM   #3
KnowFear
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There's also the hydraulic method. Bolt a plate to the top of the barrel to seal the jug, attach a grease fitting, then pump it up with a big grease gun. Haven't done it myself, but I hear it works.
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Old 09-09-2013, 10:04 PM   #4
Kai Ju
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Quote:
Originally Posted by KnowFear View Post
There's also the hydraulic method. Bolt a plate to the top of the barrel to seal the jug, attach a grease fitting, then pump it up with a big grease gun. Haven't done it myself, but I hear it works.
That one actually sounds less damaging and less work than what I suggested. Nice one.

Like I said before: Good luck and let us know if it works so KnowFear can take the credit. (If it doesn't, don't blame me)
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Old 09-09-2013, 10:28 PM   #5
Motopsychoman
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Eek

Can you get the opposite cylinder off? If so, pull it off then just unbolt the rod bottom cap. Cylinder, piston and rod should come off as one piece.
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Old 09-09-2013, 10:32 PM   #6
Kai Ju
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Quote:
Originally Posted by Motopsychoman View Post
Can you get the opposite cylinder off? If so, pull it off then just unbolt the rod bottom cap. Cylinder, piston and rod should come off as one piece.
The rod bolts come in from the piston side...
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Old 09-09-2013, 10:42 PM   #7
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Eek

Quote:
Originally Posted by Kai Ju View Post
The rod bolts come in from the piston side...
I like the hydraulic pumping idea then. Are the pistons at the bottom position? If so, there is some risk that the hydraulic method might pull the studs right out of the cases. The case aluminum is pretty soft.

If the piston is not at the bottom, then gentle tapping might slowly dislodge it, but a hard whack might damage engine internals.

Have you ever heard of a dead-blow hammer? It has a sliding weight inside a hollow head. It might be the best thing for this.
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Current Rides: '13 Sertao, '98 Bandit 1200, Being restored: '86 R80G/S PD
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Old 09-09-2013, 10:48 PM   #8
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Eek

I'm guessing that the pistons are near the top of the cylinders, otherwise you would just turn the engine and push the cylinder off.
Is the transmission off? Maybe you could rig a breaker bar across the flywheel somehow and get lots of leverage.
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Old 09-10-2013, 12:12 AM   #9
disston
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You could cut the cylinder and piston off with a sawzall or even a torch. Very little chance the parts are usable ya know.

There was another of these recently or a couple months ago anyway and the pistons and cylinder were both usable once gotten apart. I still have a hard time believing it though because once separated they didn't show any signs of having been corroded together. That is sort of impossible.
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Old 09-10-2013, 12:45 AM   #10
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Nothing to add that's helpful but I do want to see pics of before during & after please - we can all learn from it whatever the result.
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Old 09-10-2013, 04:29 AM   #11
ME 109
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Quote:
Originally Posted by disston View Post
You could cut the cylinder and piston off with a sawzall or even a torch.
Good luck with the torch!
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Old 09-10-2013, 05:02 AM   #12
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A grad school buddy of mine had a seized Goldstar engine and this is how he got his piston unstuck...worth a try before completely destroying something. He was also able to save the cylinder.

"From an antique motor forum I found the 12 Steps to Removing a Frozen Piston and it recommended scrapping away as much rust as possible (which I had done) and use a 50/50 mix of ATF and gasoline with a bit a cloth as a wick and ignite it. The heat warms and expands the whole cylinder and sleeve while the ATF works its way down past the rings. I let it burn for an hour and pounded with a large wooden drift and a dead blow hammer and I finally had movement. Several more whacks pushed the piston down and I was able to finally release it from its rusty prison."


Beezer Josh screwed with this post 09-10-2013 at 05:09 AM
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Old 09-10-2013, 05:25 AM   #13
Stan_R80/7
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Use hand tools (i.e. a hacksaw) and go slow. Hacksaw through the cylinder below the piston rings to free the cylinder from the remaining portion of the piston and connecting rod. Alternately, hacksaw through the cylinder below the piston and through the connecting rod. Good luck!
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Old 09-10-2013, 07:30 AM   #14
picinisco OP
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Quote:
Originally Posted by Beezer Josh View Post
A grad school buddy of mine had a seized Goldstar engine and this is how he got his piston unstuck...worth a try before completely destroying something. He was also able to save the cylinder.

I know about this from the same website but the problem I have is the piston is all the way at the top so cannot get the burn going for any length of time which is why I have tried several times to cook it over a camping stove of course without the aid of ATF to flow down.

For the same reason (piston at top) I do not have access to the lower part of the piston to hacksaw it off.
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Old 09-10-2013, 07:37 AM   #15
picinisco OP
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Quote:
Originally Posted by Stan_R80/7 View Post
Use hand tools (i.e. a hacksaw) and go slow. Hacksaw through the cylinder below the piston rings to free the cylinder from the remaining portion of the piston and connecting rod. Alternately, hacksaw through the cylinder below the piston and through the connecting rod. Good luck!
Oh hacksaw through the cylinder. I was really hoping to save the cylinder. It has a steel liner which could conceivably be re-bored no matter what is stuck to it.
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