Clark Clipper Restoration: Hydraulic Tilt Cylinder Rebuild (Disassembly, Repair, & Reassembly)

This video documents the complete process of tearing down, refurbishing, and reassembling one of the hydraulic tilt cylinders for a Clark Clipper restoration project. The process involves overcoming seized parts, deep cleaning, replacing seals (including custom cup creation), and putting the cylinder back into working order. Time Range Topic/Activity [0:00]–[0:37] Introduction and Project Overview: Introduces the task of rebuilding the two hydraulic tilt cylinders, including 3D printing new boots, and shows the growing pile of reconditioned parts. [0:56]–[5:17] Initial Disassembly and Seized Parts: Begins tearing down the first cylinder. Shows the heavily soiled piston rod end due to necessary heating to remove the nut. Struggles with various seized plugs and bolts, requiring heating to loosen them. [5:18]–[8:27] Removing the Cylinder Head/Cap: Confesses to pre-loosening the cap screws. Discusses the general uncomplicated nature of the cylinders, emphasizing the importance of an unscratched bore and rod. Removes the cap, dealing with leaking hydraulic fluid. [8:28]–[11:22] Gland Segment and Piston Removal: Identifies the gland segments (three pieces) that hold the cylinder head in place. Uses a press to push the piston down to access and remove the segments. Demonstrates using compressed air (cautiously) to "blow" the piston out of the cylinder bore. [11:23]–[13:14] Inspection and Seal Condition: Inspects the cylinder bore for scratches. Shows the extremely hard, old leather cups and O-rings. Discusses finding replacement cups and the need to enlarge the inner hole on the new ones (ordered from McMaster-Carr). Prepares to remove the last plugs using heat before cleaning. [14:21]–[18:02] Piston Rod End Disassembly and Gland Packing: Removes the castle nut and piston assembly from the rod end. Notes the stiff leather seals and points out the gland packing (seals). Expresses concern over an apparent missing O-ring compared to the other cylinder. Cleans the threads of the rod. [18:47]–[19:57] Custom Piston Cup Creation: Shows the process of modifying the replacement piston cups: 3D printing a centering tool and using a gasket hole punch to create the required 1.5-inch inner hole. [19:58]–[25:08] Reassembly - Piston and Rod: Begins putting the tilt cylinder back together. Installs new gland packing seals and a new O-ring on the rod. Assembles the piston: spacer, first cup, piston body, second cup, and securing it with the castle nut and cotter pin. [25:09]–[26:27] Installing the Piston/Rod Assembly: Lubricates the piston and guides it back into the cylinder bore. Notes the ease of sliding it in. Prepares to use the press to seat the cylinder cap/gland segments. [26:28]–[29:00] Final Cylinder Closure and Boot Installation: Seats the cap, installs the lock nut, and temporarily fits the roll pin. Installs the new 3D-printed boot onto the cylinder. [29:01]–[31:09] Finishing Touches: Fits the cylinder back into its mounting bracket temporarily. Installs a new zerk fitting for lubrication. #Clark Clipper #Hydraulic Cylinder #Tilt Cylinder #Restoration Project #Cylinder Rebuild #Hydraulic Repair #Disassembly #Reassembly #Piston Rod #Gland Packing #O-Rings #Leather Cups #Piston Cups #3D Printing #Custom Parts #Seized Bolt #Heating Parts #Gasket Cutter