Saving Those Heads

Saving Those Heads

How to Fix Destroyed Vintage Cylinder Heads

By Len Emanuelson

One of the real issues with running vintage kart motors is
that the parts are hard to find and are getting very expensive. There are a few
engines like TKM and a few IAME based engines that you can still buy new
replacement parts, but a typical cylinder head can be $250 or more. So it pays
to try to salvage what you have if you can. In most cases all that’s required
is a manual lathe and a $60 arbor from LAD.

I’m no machinist, but I have a lathe, and at the rate I blow
stuff up, I fix my own engines. In this case a friend brought me a TKM 150cc
cylinder head that had been pretty well beaten up by a piston failure. As you
can see in the “before” photo, we mapped out our strategy by numbering the
sequence of the surfaces to be machined. The objective is to end up with the
squish band the same relative distance from the sealing surface as it was
before machining. Another objective is to remove the least amount of material
possible, because it is the head’s total mass that acts as a heat sink, and
keeps your air-cooled motor cooling as efficiently as possible.

Follow along as we bring this cylinder head back
to life in less than one hour of time in the shop.

Step 1

First, inspect the damage to see if the head is even repairable without welding. We decided to first machine the cylinder sealing surface (#1) .020”, the head-to-muff surface (#2) .020” second and the squish band (#3) .020” third. If the squish band did not clean up at .020” we would have started over on all three surfaces with an additional .010” cut. The object is to remove the least possible amount of material and still restore the surfaces.
First, inspect the damage to see if the head is even repairable without welding. We decided to first machine the cylinder sealing surface (#1) .020”, the head-to-muff surface (#2) .020” second and the squish band (#3) .020” third. If the squish band did not clean up at .020” we would have started over on all three surfaces with an additional .010” cut. The object is to remove the least possible amount of material and still restore the surfaces.

Step 2

Here is the LAD cylinder head mandrel. It fits into the lathe chuck or collet and then the head screws on to the mandrel via the sparkplug threads.
Here is the LAD cylinder head mandrel. It fits into the lathe chuck or collet and then the head screws on to the mandrel via the sparkplug threads.

Step 3 & 4

Step3
The mandrel should stick out of the lathe chuck or collet just enough to screw on the head and clear the fins. This provides the least amount of runout for accurate machining.
The mandrel should stick out of the lathe chuck or collet just enough to screw on the head and clear the fins. This provides the least amount of runout for accurate machining.

Step 5

We first machined the head-to-barrel sealing surface. To do this we ran the lathe in reverse (clockwise) so that we could easily see the cutting tool. Important because the tool must cut all the way into the corner of the “step” for the liner. The cylinder must be very tight on the mandrel or it will unscrew from the force of the cutting tool.
We first machined the head-to-barrel sealing surface. To do this we ran the lathe in reverse (clockwise) so that we could easily see the cutting tool. Important because the tool must cut all the way into the corner of the “step” for the liner. The cylinder must be very tight on the mandrel or it will unscrew from the force of the cutting tool.

Step 6

Next we cut the surface above the muff. We ran the lathe in the normal rotation (CCW) for this operation.
Next we cut the surface above the muff. We ran the lathe in the normal rotation (CCW) for this operation.

Step 7

The angled squish band is machined with the “compound” part of the lathe. Foreign motors like the TKM, most Komets, etc. use approximately an 11.5-degree angle on the squish band. A good way to check the angle your compound (without the lathe running) is to touch-off the cutting tool on the inside edge of the squish band, back the tool carriage off .010” and then move the cutting tool to the outside edge of the squish band with the compound. It should be .010” away from the squish band if the compound angle is set correctly. If not adjust.
The angled squish band is machined with the “compound” part of the lathe. Foreign motors like the TKM, most Komets, etc. use approximately an 11.5-degree angle on the squish band. A good way to check the angle your compound (without the lathe running) is to touch-off the cutting tool on the inside edge of the squish band, back the tool carriage off .010” and then move the cutting tool to the outside edge of the squish band with the compound. It should be .010” away from the squish band if the compound angle is set correctly. If not adjust.

Step 8 & 9

Step8
After cutting the squish band the bowl-to-band parting line was still in pretty rough shape. We readjusted the cutting tool and took a light cut on the outside edge of the bowl area until the damaged area was gone.
After cutting the squish band the bowl-to-band parting line was still in pretty rough shape. We readjusted the cutting tool and took a light cut on the outside edge of the bowl area until the damaged area was gone.

Step 10

A piece of 400 grit sandpaper was used to blend the angle cuts and damage in the bowl area. Probably not how your shop teacher showed you how to do it, but as you can see in the finished photo, it works.
A piece of 400 grit sandpaper was used to blend the angle cuts and damage in the bowl area. Probably not how your shop teacher showed you how to do it, but as you can see in the finished photo, it works.

Step 11

The final check is to make sure the squish band is the correct diameter for your engine’s bore. We are using a 58.8mm piston, so the 58.85mm size is just about right. If your diameter is too small, cut the squish band deeper. If it is too big, cut the cylinder sealing surface some more. After you do a couple of these you’ll get the hang of juggling the dimensions for the desired results.
The final check is to make sure the squish band is the correct diameter for your engine’s bore. We are using a 58.8mm piston, so the 58.85mm size is just about right. If your diameter is too small, cut the squish band deeper. If it is too big, cut the cylinder sealing surface some more. After you do a couple of these you’ll get the hang of juggling the dimensions for the desired results.
2021 Avon 12th Annual Vintage Karting Reunion

2021 Avon 12th Annual Vintage Karting Reunion

By Kurt Bogerrman
Photos by Natalie Bogerman & Scott Kneisel

Historic class karts coming around the hairpin

On July 29-31, the Genesee Valley Kart Club hosted the VKA for the 2021 Avon 12th Annual Vintage Karting Reunion. 

I really hadn’t paid much attention to the weather reports as the weekend approached. Work had kept me busy, and I had barely cast my eyes on my Karting accoutrement since the previous event a month earlier. My boss was very kind to let me know on Wednesday afternoon that I was “probably going to get rained out.” At least I’ll still have some time off, I thought to myself. Sure enough, as soon as I dropped the selector lever into “Drive” early Thursday morning, the deluge started. Out of the corner of my eye, I could see a wince come across Natalie’s face. She wasn’t sure how I was going to react to this. I said, “What the hell” and proceeded to lug my tiny trailer out of the driveway and disembarked on our 4-hour trek northward.

“On your marks! Get set! … Oh – you’ve gone already…”

This journey was a mixed bag, weatherwise, as we crossed multiple bands of rain, then clear, then rain again, coming down with varying intensity. We encountered some of the heaviest precipitation while we were within a half-hour of our destination, and the sky to the northwest was grim. It was at that point that I began to doubt whether there was going to be an event after all. As we neared the Avon exit, however, the rain subsided, and by the time we arrived at the track, efforts were already underway to squeegee off the track surface. Methods included blowers, dragged gangs of tires, and an amusing new class of entries: “Late-Model SUVs.” I never would have guessed that a GMC could negotiate the hairpin. Things were looking up!

There were a total of 77 entries at this event, and many of them were on site already on Thursday. I’m not sure if my expectations have been skewed by some of the low, Covid-era attendance numbers, but I was struck by the number of early arrivals. I quickly recognized the dayglo tees of Jerry, Marc, and Ben Nagle, who had travelled from NW Ohio and had arrived the night before. I eventually learned that Scott Klingler, Jesse James, Don Renton, and Vinny Rotole had also made pilgrimages from their own Midwestern locales to Central New York.

When the track was finally dry enough to be opened for practice, we took our turns in sessions arranged by basic kart type, i.e., Historic, Rear, and Sidewinder. There was little downtime and plenty of track time. The practice sessions cycled continuously, and this was extended right up to the 6pm noise ordinance cutoff. I’ve said it before: I like Thursday practice days. 

Avon’s banked Monza turn.
Yamaha Limited, Heat one – GO!

Some of us have made it a tradition to get together for a meal on the town if we’re amongst the Thursday crowd. Once the track was closed for the evening, about a dozen of us headed down the road to the popular Italian restaurant, Fratelli’s, for some of their delicious fare. It’s fun to better get to know our karting friends away from the din of the track over good, local food and drink. In hindsight, I consumed too much of that local food and drink. Fried cauliflower chunks, each the size of tennis balls…a portion of chicken parmesan that should have been three meals…so worth it! Or was it? Friday morning came quickly. No time for regrets! Pass the antacids. LOL!

The standard event schedule enumerates morning practice and one heat on Friday afternoon, followed by a more abbreviated practice and two heats on Saturday. Weather forecasts and travel time considerations have prompted us at several recent events to vote on whether we’d prefer to do two heats on Friday and one on Saturday. The modified schedule has become a popular option, and, once again, the majority was in favor of front-loading the schedule.  

Historic class negotiates the Hairpin.

There were 13 classes on the grid schedule, including some combined classes. Historic Rears and Sportsman Rear classes were especially well represented, a growing point of pride in the Northeast. Yamaha participation was strong, of course, with several dual engine entries, as well. A couple of foreign engine duals as well as a couple of four stroke entries were present, too. 

One particularly interesting aspect of this event was the surprising number of Dual Engine Rear machines. There were 8! That’s right – Eight! Our guests from the Midwest were well represented in this category, many of those guys fielding seriously race prepped SAE frames. Several of these thoroughbreds had McCulloch motivation while others featured dual West Bent 820 propulsion. Notably, all eight of these karts finished the first heat, which is a special feat in itself! Their oscillating cacophony of pressure pulses, squealing tires, and general sense of barely controlled chaos produced a palette of sight and sound that was a delight to behold. Even with that kind of excitement on tap, we were able to roll through the first two heats without incident, and upon their completion we segued into the Kart Show and the traditional Avon “Pizza and Pop Party”.

Various rear engine karts on deck.

The Kart Show was very well attended with about 60 karts flanking the Start/Finish line. This doesn’t top our previous Avon record, but it was, I believe, very respectable in this Covid era. I always encourage everybody to participate in the Kart Show and get their machines out there for everyone to appreciate, especially visiting spectators. Natalie, my amazingly supportive wife, helps to distribute the kart show entry forms and People’s Choice ballots, and checks in frequently to be sure that I stay on task. I usually end up serving as one of the Kart Show judges, and I typically seek to enlist two others, one of whom who is confident with Rear Engine stuff, and another who is more familiar with the sidewinders. On this occasion I was assisted by Paul Hunter and Skip Owen.

The challenge of picking any type of “Best” kart never gets easier, and there were so many great karts at Avon! It bears mentioning that two of those Dual Engine Rears posed a particular quandary for this trio of Kart Show judges. Both Vinny Rotole and Brian Santee had exceptional, yet philosophically different entries in the Rear Engine Modified class. Vinny’s was a very beautiful, very customized, strikingly red and black SAE. It featured a gorgeous pair of MC101s on Hegar mounts and beautifully embroidered leather upholstery. It was low and wide, with no shortage of hydraulic stopping power at all four corners. Vinny’s kart evoked images of Ferrari, Maserati, or Alpha Romeo.  Brian Santee’s 1965 Rupp Chaparral, on the other hand, was the analog of a COPO Camaro or something from Carol Shelby’s skunkworks. His machine sports dual MC91s and Hurst/Airheart brakes. Its metallic, piney green paint is complimented by the bright chrome of the steering hoop and the various polished aluminum accessories, as well as by that classic, pleated “Deluxe” Rupp upholstery. Both karts were exquisite in their own ways, but, as judges, we erred on the side of “Period Correctness.” Brian’s Rupp was a restored, factory race team muscle car, while Vinny’s was a retro-mod supercar. At least, that’s my excuse and I continue to struggle with it! The complete show results are published elsewhere in this report.

Kart Show on the straightaway. The judges have their hands full!
“I know! Group photo, everyone!”

Saturday’s schedule was much the same as Friday’s and, again, we were able to complete the third heat without incident. The points were tallied, and the trophies and medals were awarded. Those who had long trips ahead of them got to work packing up their trucks and trailers, while others enjoyed some additional open track time.

Instead of repeating the podium results, which are available elsewhere in this issue, I’d rather acknowledge and thank the people whose efforts made this 12th Annual Vintage Karting Reunion possible. Scott Kneisel and Sam Polito are the promoting team for this VKA event and are the vintage liaisons at GVKC. Scott handles the clerical work, forms, class arrangement, and communication. Sam is responsible for the facility and grounds maintenance (track drying!) as well as safety inspections, and also helped out with flagging, as needed. Don Foley was our flagman, and John Salisbury was the First Turn Marshal.  Darla Frederick, out of sight in the timing tower, kept things rolling like a well-oiled machine. Al Gutberlet, the facility owner and GVKC President was courteous and accommodating, as always. VKA National Events Director, Karl Ginter, supplied the trophies. Maria DeFrancisco handled the 50/50 ticket sales. There are certainly others, unnamed here, who are deserving of our recognition and gratitude: the folks in the snack bar, as one example, come to mind. These events don’t organize and execute themselves. 

This event was fun and exciting. The weather turned out to be exceptional and the turnout approached pre-covid numbers. There was a notable variety of karts on hand, and the competition was clean. It was great to meet new folks from out of the region, just as it was fun to see familiar faces. I’m glad I didn’t pay attention to Wednesday’s weather forecast.

Look at those beautiful clouds….of smoke!
More Yamaha Limited
Dual Rears on the front straight.
Rodrigo’s Sportsman Rear kart, waiting for action.
No one “needs” a trophy… But they sure are pretty!
TNT Kartways Vintage Olympics

TNT Kartways Vintage Olympics

by Jim Kammueller

Congratulations to TNT Kartways in Taylor, Missouri for celebrating their 60th anniversary this year.  Also a big thank you to track staff for hosting VKA races  (August 5th, 6th and 7th) on its new state-of-the-art racing surface laid down in late 2020. 

Thursday was an open practice day with the driving events beginning after lunch due to some rain delays earlier in the morning.  There were 84 entries with 18 VKA classes represented.  Heat #1 ran on Friday followed by a kart show and a fish fry.

Saturday morning practice was followed by Heat #2 and a tribute to the late Faye “Ladybug” Pierson.  Track owner Terry Traeder began the tribute by reading an article on Faye that summarized her life in Bug kart manufacturing and racing.  Local kart racer Avery Scott closed the memorial service by driving two laps around the TNT track in my 1962 Bug Fly reproduction kart built by Steve Welte. The 3rd and final heat and the awards ceremony followed.  

Saturday was a “warm” day with the air temperature at 90 degrees.  A big thank you to Jeff Miles and staff for all of their hard work, and to Christy Miller who provided the racing photos for this write-up. 

 
Kart show. L to R front row: Donnie Cain, Tom Brabant, Shawn Welte, John Wall Jr., Ludovico Prelogar. L to R rear: Jason Kenney, Cameron Stock, Cody Brookman.

SASW racing action. #113 Tom Day, #632 Gene Lang and #47 Ron Brookman.
Combined Yamaha Limited and Piston Port Heavy racing action.

Yamaha Piston Port action.* TNT
Yamaha Masters racing action. #4 Marty Weston, #9 Denny Scott and #23 David Drewes.
100 CC Classic, Reggie Rowsey, #71.
100 CC Classic, Steve Wager # 74.
Dual Sidewinder/Dual Yamaha/150cc Sidewinder. #15 Ben Hamilton, #17 Daniel Birge and #00 Rodney Fish.
Yamaha Piston Port Light. #23 Peter Vetter, #67 Jerry Fondrey and #3 Ron Funkhouser.
100 CC Sidewinder. Dean Didion #3, Jerry Foundry # 67, Ludovico Prelogar #00 and Jim Rowe # 75.
Yamaha Masters including #59 Lorenzo Dibacco, #23 David Drewes, # 75 Jim Rowe and #4 Marty Weston.
Start of West Bend Sidewinder race. At left Randy Duncaff #68 and Kevin Rice. At right Tom day #113, John Konkle, Steve Welte and Cal Stafford.
Start of combined Yamaha Piston Port Heavy and Limited race. Matt Roberts #4 and Ron Funkhouser #3 in front.
Start of heat 1 Sportsman Sidewinder race. L to R are David Lovell # 23, Dean Didion # 62, Nick Kammueller # 117, Stuart Keller # 41, and Kevin Rice #7. In back are Bill McCornack # 6 and Jim Kammueller #04.
Combined Sportsman rear, 80 CC MAC and Junior Race. Miles Frost and Vince Arconati.
Combined Sportsman rear, 80 CC MAC, and Junior race. Jim Kammueller # 04, Rick Magnuson # 77, Shawn Welte # 6, Vince Arconati # 7, Tom Brabant # 49 and Ralph Potter # 20.
The 4 cycle karts of the Hamilton and Vandermaiden families. Nathan Hamilton #55, Ben Hamilton # 85, Taylor Vandermaiden #V4 and Richard Vandermaiden # 22.
Combined SASW and Over 60 Race. L to R front are Ludovico Prelogar, Tom Day and Ron Brookman.

2022 Vintage Kart Wall Calendar-

PRIOR TO TAKING ORDERS IN SEP. OR OCT., I’ve been busy trying to get support from the tracks VKA has used. NINE tracks have committed so far. They will each get a full page aerial picture. I’ve got a great idea for the THREE months that do not have sponsors. All TWELVE months will be fun for vintage AND modern karters to hang on their wall. Commitments from ADVERTISERS are next. They will be getting expanded exposure. I’m planning on printing 100 more than 2021 … over 300 total‼️ Printing and Delivery is scheduled for early December … just in time for Christmas ‼️ STAY TUNED.

9/3/21 UPDATE:  2022 Calendar layout for NINE tracks is compete.  The next step is to sign-up advertisers.  Then the effort to solicit sales will begin.  The plan is to keep the price the same … $15 each and blocks of 10 for $100.  Great, easy Christmas for kids, grandkids, friends, and relatives.

Lightning-Fast Nelson Ledges Welcomes Vintage Enduro Karters

Lightning-Fast Nelson Ledges Welcomes Vintage Enduro Karters

By John Copeland, VKA Enduro Director
Photos by Turn 13 and John Copeland

Tucked away in eastern Ohio Amish country, Nelson Ledges Road Course has  been a favorite of sports car club racers since 1958. But since 2019 this hidden gem has been added to the AKRA Road Race Series, hosted by Dart Kart Club and Vintage Enduro Karters enjoyed it once again in 2021. Coming off the historic 942-entry triumph at Mid Ohio just a month earlier, Nelson Ledges was the perfect counterpoint; a more traditional club-type racetrack, a more laid-back atmosphere, and less pressure on the organizers with closer to 300 entries.  Mind you, 300 entries would mark a successful road race event at any venue, and it was a good fit for the 2 mile, 7 turn Nelson Ledges.

Mike Schlager’s Twin B-Bomb Mean Machine

The track layout is all about speed, with long, sweeping, high-speed turns taken flat-out and only two (or one!) braking points. Many of the participants, including yours truly, thought it might be the most physically demanding track they had raced on. While most of the Midwest sweltered in a mid-summer heat wave, the tempering effects of breezes off Lake Erie made for more pleasant temperatures. But it also brought some rain off and on Saturday. The folks from Dart kart did their usual stellar job and managed to get all the Saturday races in by combining and shortening them. Sunday, predicted to be the worst weather of the weekend, turned out to be the best, with clear skies and comfortable temps.

Vintage Piston Port Saturday was part of the 10-class combined race that was first off the grid on Saturday. Eight Vintage Piston Ports were entered and they spread out pretty quickly with Ben Eberhart in the lead, followed by Arthur McKinney and John Copeland. With dozens of karts of varying speeds on the track; TAGs and L0206’s, sit-ups and laydowns, there was never a shortage of people to race with. At the end of the 20 minute Vintage event the winner was Eberhart, McKinney, and Copeland , followed by Fred Stoll and Greg Hartley.

Fred Stoll in his super-quick Vintage Twin

Vintage Open Saturday was a seven-kart field and was another multi-class combined race. Fred Stoll took out whatever frustration he had from the Piston Port race by blistering the field by more than 2 ½ seconds per lap. Ben Eberhart climbed out of his winning Piston Port machine just long enough to pour in some fuel and took it right back to the grid to trail Stoll in 2nd.  Arthur McKinney also tried back-to-back races, but retired after only 3 laps. That left Ben Eberhart’s father Duane in 3rd place, followed by John Konkle and Greg Hartley.

Mike Schlager practiced his Chaparrel with twin Mc 101’s, but raced his Mean Machine

The weather forecast for Sunday was for rain all day, but it turned out to be clear skies and warmer; a beautiful day for racing. Vintage Piston Port Sunday gridded the same 8 contestants as Saturday’s race, with largely the same results. Ben Eberhart was even faster than the day before and lapped all but 2nd place. Arthur McKinney was in the runner-up spot once again, with John Copeland rounding out the top three. Chuck Brewer edged Fred Stoll for 4th, leaving Greg Hartley 6th. Compared to the Saturday race, the track seems almost deserted with only 19 karts in the combined 8 classes taking the green, but the clearer track made for faster laps.

The 5th race on Sunday was another repeat of Saturday’s Vintage Open event, with 6 entries. Once again Fred Stoll was the class of the field, winning by 40 seconds. Ben Eberhart repeated in the runner-up spot, again running the Piston Port Yamaha he had won with just an hour earlier. Listening from the pit wall as Eberhart’s clutch slowly self-destructed was painful, but it hung on until the checker. Phil Reuter, back in a laydown kart for the first time in several years, adapted quickly and claimed 3rd ahead of John Konkle and Greg Hartley.

John Copeland in Vintage Piston Port

The 5th race also featured the only Vintage Twin as Mike Schlager hustled his Dart Mean Machine twin B-Bomb ride to everyone’s delight. Schlager’s laps, in the 1:22’s, are a tribute to his devotion to showcasing truly period-correct Vintage machine.

And so the AKRA/Dart Kart wrapped up another outstanding weekend of road racing. The AKRA Road Race circus moves on to Summit Point Raceway in August, and then the much anticipated mega-event at Pittsburgh International Race Complex, featuring the first-ever Vintage Enduro Kart Celebration in late September. Road Race karting is enjoying a much-needed resurgence as karters rediscover the unique sensation the laydown, high-speed racing brings.

John Konkle talks to another karter about the joys of Vintage Karting
Greg Hartley made the most of his return to Enduro Racing
Ben Eberhart was faster than many of the modern karts