Yep. Split the cases, installed the studs and cam washer, cleaned the sealer, resealed and bolted back up. I then realized i had the CNW bolt kit for the case which replaces the studs with bolts. First reaction is i have to re-split the case if i want to change out the studs with the bolts
. Then my mind cleared up and i realized i could just unscrew the studs using the portion that protrudes from the case. Whew.
Ok, back on track. Next up is attaching the barrels. I thought Jim Comstock's method of placing the pistons in the barrels and then attaching the pistons to the connecting rods with the barrel suspended on sockets over the crankcase was the way to go versus the more traditional method of attaching the pistons to the rods and then trying to get the rings from both pistons into the cylinder bores. The only downside with Jim's approach is tying to get the wrist pin clips in with the barrel on top of the rods, especially aftermarket clips in short skirted pistons. I placed some paper towels in the case in case the clip were to fall so they wouldn't fall in the case and proceeded to attach the clips. I previously installed the clips on the inboard side of the pistons so all i had to attach in-situ were the outboard clips. I got one clip in so i'm feeling pretty good. However, the next one was when everything went to hell. My son was helping me and was holding the barrel when i was pushing the clip in. Well i was pushing pretty hard (those clips are a bitch) and pushed the barrel off the sockets. My son, with reflex reaction, went to catch the barrel (not knowing it wasn't really going anywhere because one of the connecting rods was attached) and in doing so also pulled enough of the paper towel to allow the clip, which by now fell out, to fall in the case
F*#@K
So i pulled the barrel off the one connected piston so i could see if i could see the clip in the case. I couldn't. Next step was to place the case on the side and gently tap it to see if the clip would moved to where i could see it. Nope. Crap! Do i have to re-split the case again to get the effer out? Luckily, I remembered i had a boroscope so i put that into action to see if i could find it. Sure enough
Looks like it's stuck pretty good in oil/sealant
I tried banging it on it's side, but it didn't budge. So, I cut off a piece of a wire coat hanger and using the boroscope i was able to push it enough from out under the flywheel so i could get to it with a long set of needle noose pliers. Whew!
So with the barrel off and one piston connected to the connecting rod, do i pull that out and go back to step one with trying to get those damned clips installed in situ, or do i forgo the Comstock method and use the more traditional approach of attaching the pistons to the rods first and then attaching the barrel. I decided to go the later route. I also read that the rings could be pushed in the bores with your fingers. It seemed i needed four hands to get the rings in on one piston, let alone two. I gave it a try though but it seemed i was squeezing a ballon. When i pushed on one side, the rings would pop out on the other side. I ended up giving up on this approach and pulled out some old hose clamps to use as ring compressors. I made sure that when tighted down, they rotated freely (i.e. none of the rings were somehow not in their grooves). Still though, you don't know if the ring may bend when sliding in the bores. After i got them in, i rotated the assembely and it didn't seem like there was anything amiss with the rings, so i hope i'm good. Oh, and the gaps are supposed to be orientated in a certain way. That went out the window in all of this. And i used sealant on the base, not a gasket, so by this point i had sealant all over the place. All in all, this entire process was a pain in the butt.
Barrel on!