The Maestro's Quiz- June 10, 1996- Part 1 Answers

The QUIZ:
 One day last week, The Maestro bought a "core" 1966 912 engine
for a not unreasonable price, gambling on the chance that the crank
might be OK.
 The engine had two or three holes in the top of the Case from
#3 Connecting Rod that, although still attached to the crank,
had been bent NINETY DEGREES at the small end, pulling
the wrist pin out of the piston and smashing said piston into bite-size
pieces, making the Case Holy as a result. 
 But that's not the Question right now. What really caught the Maestro's 
eye was that the generator pulley was "offset" to the REAR
by half an inch, and when the Maestro looked down the plane of the
pulley he saw it was indeed badly misaligned with the Crank drive pulley!
He inspected the rebuilt generator that was on the 912 and found it to
be a Stock, small diameter, 12-Volt 912 Unit.

Questions:
1. How come the Generator Pulley was half an inch to the REAR of the
of the Crank Drive Unit?
2. Did anything happen to the generator pulley (pulleys)?

The ANSWERS:  
      The Generator Pulley was a half-inch to the REAR of the
Crank Drive Pulley because the Turkey had used two OUTER PULLEY HALVES!!!
(the ones withOUT the two "notches" used to keep the pulley from turning when
you're trying to take off a broken fan belt. Usually however, the previous
owner used a 1" Impact Wrench with 3000 PSI air pressure to tighten up
the pulley nut and all you succeed in doing is rounding off or dinging 
up the notches in the inner pulley half.)
  Using Two OUTER Pulley Halves in place of the Correct Combo of
one INNER Pulley Half and one OUTER Pulley Half makes the incorrect pulley 
combo sit way too far to the REAR, causing gross misalignment of fan belt.
(Don't believe me? Try it!)
  Also- using this WRONG pulley combination makes it IMpossible to
tighten the pulley/fan belt/pulley nut assembly properly. Which means that
the Inner Hub joins the Union at Murphy's Machine Shop, and machines
out the center hub of BOTH pulley halves! Which means that the pulley halves,
having been castrated in the center of their being, no longer turn the
generator. Since the pulley halves no longer turn the generator,
they also no longer turn the FAN that's on the other end of the generator!
  Which means that the Air-Cooled Porsche engine, no longer gets its
needed cooling air. Which means said Porsche engine runs HOTTER'N'HELL!
 Which could have played a role in the Ultimate Demise of this
particular engine. But not in this case.

Quiz: Part 2:

 One cylinder head- the damaged one- was off the engine, but the
other head was still attached and couldn't be inspected in detail. 
All the Maestro could do was to check for the obvious screw-ups- like 
broken valve guide bosses. The Maestro looked down the Intake Port and
found- you guessed it- not one but TWO broken Intake Valve Guide Bosses!
 The Maestro popped the valve cover off the still-attached
head to evaluate the Rockers. 
 Which is where he first noticed something funny. The 912 Rockers
were held down by 13 mm nuts with self-locking inserts, which were 
obviously not stock. He also noticed that the intake rockers 
DIDN'T HAVE THE SADDLE WASHERS ON THEM!
The 13mm nuts were pressing directly on the rocker shafts! 
 Geez, what a Turkey job this is!
 The Maestro eyeballed the rockers and pushrods to see what they 
were like. Which is when he noticed that one PUSHROD was MISSING!
Gone! Not There. Vamoosed! 
 Now, HOW can you have a MISSING push rod in an engine that
supposedly was RUNNING on all 4 before!

That's Question #3.
KEEP THE 356 FAITH!
The Maestro