Case 644 repairs / rebuild...

[RoamingGnome]

I'm starting some repairs / improvements to the Yellow 644 loader, (aka Sunshine)

One of the first projects is reconstruction of a previously modified battery support tray.

Fortunately, I took some photos of the stock battery support in the Red 644

but didn't take any measurements - I can figure out most of the dimensions based on what was left on the old support,
but was wondering if any of you have a 644 handy that you could take a couple of quick measurements for me?
"A" is the gap between the bottom of the support and where the battery actually sits,
"B" is the depth of the plate
"C" is the height of the side before the angle cut starts
Unfortunately the Red 644 is 5 hours away up at the property and I'm hoping to get the Yellow 644 fixed up before winter sets in...

Based on the photos I took - I'm guessing "A" is about an inch, "B" is 5.5" and "C" is 2" ???

I'll be sharing more pix and stories as I make some progress
Thanks in advance - Gerry

[Spike188]

@RoamingGnome Gerry, What year model is it?

[RoamingGnome]

@RoamingGnome Gerry, What year model is it?

Both loaders are 1974 model 644's - I bought both of them from @Eugen last summer before he moved away - He did a great job of documenting his repairs to them - I'm just tweaking a few things to carry them on a few more years...

[RoamingGnome]

Been working on the Battery support the last little while of course around here nothing ever seems to be easy or straight forward...
Started by dragging a 4x8 sheet of 1/8" steel from behind the shed and cutting a 6" slice from the end of it.

Somehow It seemed to weigh more than when I put it there 20 years ago
Engine hoist to the rescue... Google says the sheet weighs about 200 lbs
Made some educated guesses on the shape and size and laid everything out using CAD - (Cardboard Aided Design)
Then crossed fingers and eyes and hoped everything stayed square as I gave the steel a few bends in the PA 12 ton press.

(My homemade 90° die set is only 4" wide - the plate was 5.5" I really need to make a bigger/wider die when I have the chance...)

I was very happy how it turned out - - making multiple bends on a plate like this always causes anxiety for me

Gave it a couple of quick tack welds so I can test fit and check clearances when the lights come back on in the BigSky™ Shop tomorrow morning.

I'll have a chance to check the space between the battery and the motor tomorrow, I wonder if making the edge flush with the battery would give better airflow between motor and battery? - If everything is good - I'll finish the welding, splash some paint on it and start on the next bit of the project.

Quick question for people that have a 644 - Does your battery sit flush with the edge of the support? I made my plate 5 1/2" deep so there is a 1/2" lip - the battery is a hair over 5" deep.

[DavidBarkey]

Looks good Gerry .

[Harry]

Amazing work Jerry. I’m impressed with your skill set. Harry

[RoamingGnome]

- Finding things that are broken, fixing things that aren't, and then finding more things that are...
I struggle sometimes to figure out just where time disappears to...

Last update In October I had just finished fabricating a new battery tray for the yellow 644 - when I was getting ready to reassemble components on the backside of the 'new' battery tray I discovered the resistor on the backside of the regulator was broken -

It might have been damaged while trying to separate wires between regulator/starter solenoid and the ammeter/ignition switch
Wires between the components inside the tower were short and it was a real pain to separate things.

A new voltage regulator was ordered. I mapped out the existing wiring to compare with factory schematics and took everything inside to work inside on the bench where it was warm. - It was a miserable winter for working outside in the BigSky shop

While waiting for the new regulator to come in I did a test fit with the old regulator

Then I replaced all the wiring - left the wires on the long side, and figured out how to group wires together and incorporate Deutz connectors so next time the battery tray is removed from the tower I can just unplug everything and not be fiddling with little screws in tight places.

Finally, the weather got nice enough to spend some time putting things back together...

passed all the wires down inside the tower and then bolted on the new battery tray.

Plugs for everything are easy to get to behind the access plate for the tower

A quick look underneath to make sure none of the wiring would get pinched or rub when things were moving

One last look up top and everything looks good...

The tractor started up with no problems - no electrical issues anyway

- that meant it was time to take off the head and look for the cause of the excessive smoking...

[RoamingGnome]

Yeah... about that smoking issue...

It had been hoped the head gasket just needed replacement, or perhaps the head itself was a little warped...
Feeling adventurous after the success with electrical I popped the head off to see what I could see
- found a nice puddle of oil sitting on top of the piston...

then pushed the piston down

Holy scuff marks Batman
I think this engine is going to need a little more work than just a quick hone
Any suggestions / recommendations on a good small engine machine shop in Ontario?
In the meantime I'm also watching FB Marketplace for an good Kohler engine hoping I can do a quick engine swap and then rebuild this one for a spare...

[DavidBarkey]

The last Kohler I did I got the kit from Mike at enginebore.com then had Parry Automotive in Orillia do the machining . I supply them with the new piston and clearances and they bore/hone to fit . I think Mike does Machining down there as well . He is in the GTA

[RoamingGnome]

The last Kohler I did I got the kit from Mike at enginebore.com then had Parry Automotive in Orillia do the machining . I supply them with the new piston and clearances and they bore/hone to fit . I think Mike does Machining down there as well . He is in the GTA

@DavidBarkey - Thanks for the info! That gives me somewhere to start for pricing things out...