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Evil King of bad bodging
Posted by : Nut and Cheri - Cheltenham (212.139.245.156) 
Inappropriate or SPAM?
On Sunday 07/07/13 at 02:52:23
There are too forms of bodging; good and bad. The good is appreciated by all. Those are the ones where ingenuity has overcome the lack or correct parts or tools to allow a fix to be made. The bad is when a much better job could have been made; but sheer incompetence and/or laziness has prevailed. The latter can only really be appreciated if it’s been carried with style and excess.
It was a beautiful day today and Cheri is away, so I collected a broken ATC70 engine from the shed and decided to sit in the sun and see what was wrong. It was immediately apparent that bad bodging had taken place although early signs were that it had certainly been excessive if not stylish. My eyes were drawn to the welded on gear lever, plain nuts on the cylinder head (one with a washer) and the missing bolt at the bottom of the barrel. Further examination showed that the chain had often come off and worn a hole right through to the needle roller bearing on the end of the gearbox primary shaft. The chain had also punched a whole through to the flywheel. Finally the gearbox would not turn at all.
Things were certainly looking good and I eagerly pressed on to see what surprises lay inside. The top end was awesome: Removing the bolt in the side of the barrel which holds the idler pulley revealed that the bolt had missed the pulley or there wasn’t one because the bolt had almost been worn through by the chain. Off with the cam sprocket cover and yes lol one of the little bolts holding the sprocket on had been snapped off in the cam. Whilst looking at the head I thought it odd that one of the tappet covers was sitting so high; It had two O Rings on it! With the head removed I was able to remove the barrel and confirm there was no idle pulley. The barrel had been rebored but unfortunately the builder had felt the circlips in the piston were overkill and left them out (presumablt in a bowl with the pulley. So the gudgeon pin had worn two dirty great grooves in the barrel.
Onto the bottom end. The flywheel had a large flat one one side presumably from being hit in an attempt to remove it. The end of the crank had been ground off presumably to reveal some good thread after it had been damaged, again presumably in an attempt to remove the flywheel. Once inside I found that the teeth on the oil pump sprocket had vanished all together and so had the rubber button on the end of the cam chain tensioner plunger.
Onto the clutch side. Removed the cover (after sawing off the gear lever) and all was normal apart from a lot of debri in the filter including the remains of the cam chain tensioner plunger button. I removed the clutch and tried turning the gearbox primary shaft; after a lot of knocking back and forth there was a cling of something falling out and the shaft turned with some strange noises. I turned the engine this way and that until I was able to grab the thing that had gone cling. It was half a selector fork! That is a new one even for me; bent yes, but snapped off! I split the cases and peeked inside. I was not to be disappointed even here. As well as the snapped selector fork there was a tooth missing from first gear on the secondary shaft.
What can I say; awesome.
If anyone claims to have had an engine with more damage than this, then I’m sorry I just don’t believe you. The guy that owned that ATC70 engine was definitely the Evil King of bad bodging or what is commonly known as …a TWAT.
Seriously shocked
Nut
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