Have had a look at eccentric engineering website, it would be an idea to have the tool holder and cobalt cutter for those difficult jobs,
I will take up your suggestion re starting with another piece hacksaw cut, did wonder if cutting with gas would create the same problem.
The material was from a Ford offset disc.
Thanks for your help.
Looks like you snagged a piece of bisaloy or similar. High speed steel is a bit soft for it. Carbide insert tooling will cut it easily. Oxy cutting it means it will turn glass hard.
Heated housing let it cool, straightened, a hammer hit moved it. Valve head profile hasn't altered over the years!
Have to clean up crank and fit big end.
Needed those Sky Tiger tools, no corners left on any now, they are touchy.
Looking at insert diagrams those available have a lip all the way around the edge.
Square are 12.9 mil, triangular 16 mil, holders seem solid enough.
Thanks for sharing the story Wouldyou, and the pictures make all the difference.
It really is a labour of love, and in the case of old engines the journey seems to be more important than the destination.
I'd rather have tools that I don't need, than not have the tools I do need.
Had to get the pulley off after welding nuts each side of the key head for it's removal, fairly tight so will use jack to press it back on.
The broken gear, turned the side to shrink a band on, had a bit of bother getting it started while keeping it hot. Cut a 1/4 inch deep groove in the other side and tapered the inner edge of the band for a tight cold press fit.
Took advice from a member on the Smokstak forum and cut a new keyway opposite the old one, to take stress away from break.
Will post this there also, have to get it right first go as can't find the preview option we have here.
Am now thinking as a first priority I should have seen if the piston would move.
Very quiet on the forum, a bit of progress here.
Made up a transport with wheels I had, Western Power belt these H irons in two to a pole to give them a bit more life, could need a brace underneath.
A cooling tank to make and nut out the fuel delivery system, that galvanised unit is the tank, it works on gravity so must have a check valve in the line and use suction on the inlet stroke.
Fuel is kerosene, hot bulb ignition, four stroke.