Engine Construction Part V
Assembling the piston, rod, crank: The pistons have been installed once and not removed. Everything in that area fit perfectly. A screw type adjustable hose clamp was used as a ring compressor on the piston. The upper end of the cylinder bushing was beveled slightly using a 1/2" sanding drum in the rotary tool to make it easier for the rings to slide into the bushing. The cylinder was coated with way oil, the hose clap tightened around the piston and rings and the piston then carefully tapped into the cylinder. No problem.
A couple Viton O-Rings and the packing gland had already been fitted into the lower head. The piston rod and crosshead were then pushed up into the crosshead guide with the rod going through the packing gland and eventually into the piston. The piston wrench (Engine Construction I) was then used to screw the piston onto the end of the rod. Once the piston was tight on the rod, the wrench was used to hold the piston while at lock washer was put on the rod and a nut screwed on the end of the rod and tightened against the piston. This part went without a hitch.
The crankshaft and connecting rod bearings required a bit more effort to fit. When initially put together the crosshead is a tight fit and the rod has very little side movement. The sides of the main bearings and rod bearings should be trimmed/shimmed as necessary so that the rods remain in that position with no more than a couple thousands end float in the crankshaft and slide slop in the rod bearings.
Finishing up the valves in next in Engine Construction VI