So, I put the 40 hp Gale power head with the stuck flywheel in the freezer
for two days with the flywheel puller attached and tensioned, ready for
action. I had the torch ready to go in the garage. Rushed said power head
out to the garage, fired up the torch…… nothing happened. Tightened
the puller up more….. same old story, snapped off one of the 1/4″
shoulder bolts. Decided to drill out the three 1/4″ holes for 5/16″ shoulder
bolts, which I had purchased, “just in case”. Drilled out the first hole
with my “F” drill bit. Started tapping with my USA made tap. Had 1/16″ to
go tapping the first hole, and yes, I snapped off the tap.
Made several futile attempts removing the tap, including welding a nut on.
Gave up, and decided to destroy the flywheel to end this long tiresome
saga. Drilled holes all around the crankshaft in the same arc as the three
puller bolt holes. Spend much time connecting the dots, a.k.a. “Holes”
with punches, chisels, and more drilling at angles. The broken tap fought
to the end hole the flywheel on, but I finally managed to break the flywheel
free. Was then stuck with the steel hub over the crankshaft. Attached
my bearing puller to it and it wouldn’t budge…… not that I really expected it
to. Then put the air grinder and cut off wheel to work, cutting thru the hub
where the flywheel key was, so the keep the grinding wheel away from the
crankshaft taper. The hub did not want to budge until I cut a slot on the other
side and got the torch out and started “heating”…… after two months of
monkeying around with this flywheel, I was finally satisfied with a mighty “POP”.
I was afraid of ruining some good coils, but alas, I need not have worried
about that…… they were originals.
I’m only going to finish this project “if” I find a cheap flywheel.
I would love to hear the old Gale run, but it being a “non electric start” model,
not sure I’d be able to pull start it anyway!
Prepare to be boarded!