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Solder and a micrometer are easy and accurate at this point. The protruding groove around the perimeter is the original surface. I had a dial indicator and a magnetic base to find TDC. You can come practically as close with a screwdriver or pencil. Whatever you use mark where it is on either...

"I can see the pistons moving about 1mm up and down so it seems like the pistons aren't seized to the cylinder." You have better eyes than me. Pistons may not be seized but rings could be. Is the movement you are seeing just the ring groove clearance? Pull the head and your questions will be...

The family GTI had low compression and bigger rotary valve clearance than that and it started in the water. I seem to remember it was .019 inch. Sure you had spin it fast and a lot when it was cold out of the water, but it would start. Once it started on the trailer at the dock, it would start...

Since you have a single carburetor and maybe only one cylinder bad, I'd be looking at the oil injection on that one cylinder in that case. See if the little tube cracked or something like that.

I did enough testing to convince myself it isn’t a connector issue. I took the MPEM connector off and it looked brand new inside. Sure enough it started sprinkling when the connector was off. I sprayed some contact cleaner, put a little dielectric grease on the pins and put it back together...

“I like to get everything on the ski working as it should.” I worked Mechanical/Hydraulic commercial airplane factory functional tests for the last few decades of my career. They assured that the planes were assembled and rigged correctly. Finding pushed back/bent pins, cut wires, crap relays...

Got it out on the water couple days ago. My issue changed but didn’t go away. Before speedometer worked consistently from 0 to around 20 then would cut out and go to zero. Now it doesn’t like 0 to 10 most of the time. It likes to start working at 10. Works to about 25 then cuts out and goes to...

The line is a stainless sleeve that the seal rides on. I am assuming that the shaft is new from the picture. The shaft should have zero taper. I would carefully measure the shaft first before doing anything with the bearings since that is easier. Be sure it is not bigger at the thrust end...

I had a pump with a broken ear and was playing around with it while waiting for a replacement. I reinstalled them with 3/8 all thread, washers and a socket. Seat the bearing flush with the housing using a washer bigger than the bore. Get a socket and set them to depth. For example with a 16...

I thought about you a couple weeks back while working on trailer bearings. It started off with a plan to replace just the seals and repack the bearings. But one bearing looked sad so I decided to replace all bearings. I got the outer cups out of the hubs using a TIG to shrink them. New cups went...

Looks like the picture in the shop manual showing the manifold bolt torquing sequence

Did you look closely around this screw?

Since you are dealing with a 3/4 pipe thread, I doubt penetrating fluid will creep in when water can'tcreep out. Still I'd try it. JB Weld has tensile strength around 5KSI. 1010 steel has 45KSI yield strength. You need 9 times the area of JB Weld to get it to the equivalent area of steel. I...

Let's just estimate the torque at 150 ft-lb. It is probably more. So the edge of the 1 1/16th hex is .53 inches from the center of rotation. Convert ft-lb to in-lb then divide by the moment are to get the force. (150X12) /.53 = 3400 LB of force at the edge of the hex if you are tapping just one...

CRC Freeze-Off? They are a bugger. 6 point and an impact is the way I did it the first time but now you know that. Bradford White uses an anode built into the outlet nipple. You might be able to add one of those if you can get the dielectric nipple out.

"it’s not a high pressure/ heat situation" Correct, it is the weight of the hose and vibration situation. Are you OK with the failure of a water hose inside the hull? Is the water flowing into the engine where a failure would overheat the engine or is it an outlet that would pour water inside...

Thermal differential is the key. Unless you have dry ice or liquid nitrogen, you'll get about 100 degree differential at most cooling the shaft. But heat the bearing up (not ones with plastic shields) to 300 degrees F in an oven or an air fryer, now you are talking a 400 degree F differential...

I was worried about the same small seal compression question you had since my ski didn't have the big gasket before. I got the feeler gauges out after I installed the pump with the new gasket. The gap measured slightly less than the small seal height and I couldn't get a .001" feeler to fit...

This is the rest of the pump story. I took a weekend “researching” and messing with the broken pump. I tried a couple different ways to remove the wear ring as long as I didn’t have to be concerned with messing up the broken housing. I found a burr on an electric die grinder was my favorite way...

My son-in-law got a 97 GTI and a trailer for $1 from a family that had owned it since new. It had only been professionally maintained, it had never been rebuilt, looked almost new on the outside and it had not run in 8 years. It had been running fine but it just failed to start one day. I am the...