From:Nick Mulcahy
E-Mail:<npmulcahy@hotmail.com>
Subject:RE: RE: RE: Baffle plate spacing washers
Response to:1053
Date:Wed Oct 26 00:37:24 2005
Steve, I have just read your letter regarding the baffle
plates and the spacers used. I have just checked what parts
were in my motor when I dismantled it.I don't believe that
the baffle plates had ever been removed from my crankcase
before so all the parts are as it left the factory. I have
also had a look at the two drawings that you mentioned. The
spacers have the following dimensions; id .250",od .4375"
and a thickness of .1875".My engine  #D22731 has six screws
per baffle, five K-1063(#10x24x5/16") and one
K-1062(#10x24x7/8"). If you look at the early drawing there
is hole tapped midway between the cylinder studs of #1+2 and
#3+4 cylinders on the camshaft side. This is where the long
screws and spacers are used and only one spacer is used for
each baffle. Just as a matter of interest the long screws
used in my motor do not have the heads drilled for cotter
pins. This is not really a problem now we have Loctite. I 
hope this information is of some use to you, Regards  Nick
Mulcahy.

----- ORIGINAL MESSAGE FOLLOWS -----
Just putting the paperwork away and I noticed a funny thing.
 have two different copies of 'Service Bulletin No 2'! At
first glance they look the same but, they're not! Both are
headed 'Henderson DeLuxe and "K" Oil Distribution' and both
dated 'Dec 20 1921'. Both show a drawing of the crankshaft
with oilways and plug K-1301 and a cross sectional drawing
of the centre bearing oil inlet elbow with plug K-1091. All
this is identical on the two sheets, right down to the
handwriting style. They both have a drawing labelled 'Upper
half crankcase with pan removed' and a cross sectional
drawing of how the baffle plates are fitted. These last two
drawings differ on the two sheets.

One shows the two baffle plates covering only the cylinder
openings. It has just one bend at approximately 45 degrees
plus a small stiffening bend on three sides. Each plate is
fixed with two screws, K-1063, screwed into the sloping side
f the crankcase and one central screw, K-1062, with the
spacer, K-1061, screwed vertically into the underside of the
orizontal face of the crankcase. The two K-1063 screws are
shown lock wired together. The K-1062 screw has a cotter pin
hrough it, folded over the edge of the baffle plate. Text
says ' Secure baffles K-1060, spacing collars K-1061 by the
use of screws K-1062 & K-1063, also lock washers, cotter
pins and wires'

The other sheet shows baffle plates which are much more
complex in shape. These two plates cover not only the
cylinder openings but also wraps around the camshaft. Each
plate is fixed with five screws, K-1063. Two screw into the
sloping side of the crankcase as with the other version. The
ther three screw horizontally into the vertical side of the
crankcase. On this sheet, the text says 'Secure baffles
K-1060, by the use of screws K-1063, also lock washers and
wires'

Both sheets refer to the baffle plates as K-1060 though they
re both obvioulsy different. Checking the parts lists, my
1920-21 Model K parts list (text only unfortunately) has no
reference to baffle plates at all. The Deluxe parts list
(with pictures - hooray!) lists them as part no KD-1060 (Two
sed). The KJ list (pictures again)lists the baffle plates
as part nos KJ-1060 (three) and KJ-1065 (one). The Deluxe
lists KD-1063 baffle plate screws, five used (but that's per
late) and the KJ lists K-1063 baffle plate screws, 16 used.
None of the lists include a spacer K-1061!

So - what can we deduce from all this? My guess is that the
20/21 model Ks when first released had excess oil
consumption problems. The company put out a service bulletin
howing the use of baffle plates in an attempt to solve the
problem. Maybe the original baffle plate design was not
successful - certainly the three screw fixing left the end
pieces flapping and I can imagine them vibrating, 
fracturing and falling off! So maybe the baffle plate design
as changed and the number of screws increased to give a
more solid fixing. This might have happened over a very
short time so the original bulletin sheet revamped to show
the later ideas and the same date kept. The December 20 1921
ate would explain why there is no mention of any baffle
plates in the Model K parts list (already printed), but does
ppear in the Deluxe parts list, though by this time the
early baffle design with the K-1061 spacer had come and gone
o that particular part was not included. So for all of you
saying 'K1061 spacer? What is he on about?' - now you know. 
ll this makes sense until you realise that the Henderson
Dealer's bulletin referred to in my earlier posting which
makes reference to the need to remember the K1061 spacers is
ated November 1926....

All this research is great fun but I really should be
getting on with some proper (paid for) work.....
Till next time, happy riding/workshopping - Steve
----- ORIGINAL MESSAGE FOLLOWS -----


----- ORIGINAL MESSAGE FOLLOWS -----
Can anyone help with the dimensions for the crankcase baffle
te spacing washers part no KD-1061 please?
I do like my restoration work to be accurate.........
Thanks in advance guys. Steve

No responses!! - I know I joked about it but it was a
serious question. I have a Henderson dealer's bulletin which
phasises the need to remember to fit these spacers. I
quote:

'If the baffle is installed without the spacing washer, it
fit's tightly up under the cylinder openings and the suction
 stronger than if the spacer is used to hold the baffle a
slight distance away from the crankcase. This will be
helpful in machines which have given any trouble due to "oil
mping" '

Diameters are not an issue but what is the length of the
spacer - referred to as 'slight distance' in the bulletin?
Are we talking 1/8"? 1/4"? Is it that critical anyway? Ang
help gratefully received - thanks guys - Steve