The cylinders of a Merlin come in four main parts. The main part of the cylinder  holds the pistons. Then there is the top part which holds the valves and the valve springs. Then comes the rocker and camshaft assembly and lastly there is the rocker cover that seals it all.

This is the left cylinder set which is ready to be assembled on the engine.

On this day in the work shop we said happy birthday to Aaron and then got to work. We decided to put the cylinder on the left hand side of the engine and so we all looked at the manuals and pictures and we decided on which way round the cylinder should go. Trusting our judgement we lifted the cylinders up into position (any one that has worked on a merlin will agree that the cylinders aren't light) and gave it some encouragement to go on. All was going well until the cylinder was about an inch and a half from the bottom. We found that it was catching on two bits on each end, so blaming Aaron we moaned. Then we decided to take it off and that was a hassle and a half as we had trouble keeping it straight and level to remove it easily.

Putting The Cylinders On

We had a lot of trouble taking the cylinders off as we had to it at the angle of the studs, otherwise it would not come off. And we all had to use every bit of strength in our bodies to eventually take it off.

This is the left hand assembly, eventually together on the engine block.

As we learnt from our mistakes on the left hand side, Scott greased up the inside of the cylinders so they would go on a lot easier.

This is Malcolm who is cleaning the threads for the studs with a self-made tap.

After moving the engine downstairs we used the big Crane to help us because most parts are extremely heavy.

Scott and Aaron lining up the cylinders with the studs before lowering into place.

Scott, Aaron and Paul giving the cylinders some persuasion to go on as it got stuck as it went down on an angle. And it was impossible to move without some help with the hide faced hammer.