Buildup -- Step 11: Engine & exhaust

Okay, this is big, real big, to coin a phrase from a certain retired Star Trek captain. That beautiful, big engine that's been sitting around, doing absolutely nothing all of this time is finally going to be put into its place!

Use Loctite on the engine mounting screws! The manual omits this -- make sure you don't! Take your time in getting the gear mesh set properly. The manual recommends inserting a sheet of paper between the gears to keep you from meshing it up too tightly. This may help or it may be a pain, depending upon what type of paper you use. I decided to do it by feel instead. The idea is to have just a little bit of play between the clutchbell gears and the spurs. Note that the engine mount holes allow enough play to not only slide the engine from side to side, but also to twist it. Mount it straight. There should be even play between each mated pair of gears. I cannot stress this enough, take your time and get it right. Once you're confident in the position, tighten the mounting screws very firmly, but not with such strength that you strip the mounts. The Loctite will help with the final bond.

At this point we install a lightweight roll bar, and then move on to the exhaust. Make sure you pay attention to the inset in the lower right-hand corner of step 26 on page 20 of the manual, showing you the proper orientation of the elbow coupler. Be sure to also use a dab of Loctite on the set screw that threads into the end of the muffler. When you're done, the muffler should be sitting straight and comfortable, suspende alongside the chassis, not rubbing anything along its length.

Fig 47

I can smell the break-in process coming near. I can tell you right now, though, that stock header and stock pipe are ripe for some Dremel work!