WARNING: This is my first post here, and it's pretty long.
I have a 12 hp to rebuild after about 11 zillion other projects around here, so it might not be real soon. It will go in my 109 chassis with a ported hydro and lift, in hopes of making it into a 129, 139, or 1?.?9. I'm just asking now in case somebody comes up with some obscure part I need to start scouring for. I have met Tedd, Tom, Bryan, Steve B, and Don V, picked part of their brains, and visited Steve's and Don's shops. All knowledgeable people. I have read David Kirk's article. I think he has done a fantastic job, and I intend to follow much of his advice. His comments, especially regarding the cooling system and other detail work, make a lot of sense. I'm thinking of a slightly modified approach. Maybe I'm right, maybe I'm wrong. Both have happened before.
How much longevity benefit can be expected from polishing the stock connecting rod, crankshaft, and possibly the camshaft to get rid of stress risers and assorted other pimples?
What level of performance benefits are seen from things like polishing the exhaust port, matching the exhaust port to the exhaust tubing, removing casting bumps from the intake port, matching the carb/spacer/port, and polishing the valves? Larger valve sizes? Carb polishing and jetting?
Is there a practical limit for squaring the deck surface and milling the head to increase compression before running into starting and detonation problems with a stock replacement piston running pump gasoline? Regrinding the camshaft?
I'm not interested in building this engine for pulling. It's more for general use around the house (Really the yard. Sue would get ticked if I tried to vacuum the house with it.),such as mowing, snow removal, tilling, and some upcoming blade work for landscaping, maybe a plow day someday, but mostly for the enjoyment of doing it by maximizing the stock or replacement parts.
I intend to do the port matching and polishing myself, but a machine shop will need to handle the milling and boring work. I have built a few Chevy's, a Harley Panhead, and hot-rodded my lawn mower when I was in high school, but this will be my first attempt at a hopped-up Kohler.
It will be easier and cheaper to put a muffler on it than to get earplugs for all the neighbors, but I think the Kohler unit might be replaced because of the exhaust port modifications I have in mind. My main goal would be increased torque with some reasonable amount of longevity rather than high RPM. I'll probably stick around 3800.
I know that I have asked enough questions to have the answers fill several books, and many of the questions will probably have several good answers. If somebody knows of a book on the subject, please recommend it. I have the Kohler manual. I know I'm not looking for a "one size fits all" answer. Any ideas will be welcome.
If you'd rather email me than put suggestions here, please include "Kohler mods" in the subject line until I get to know your address. Since I'm not a big fan of viruses, I usually delete any messages with unfamiliar addresses.
Thanks for taking time to read this.