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Everything posted by BenHawkins

  1. The commercial vehicle projects are on a bit of a back burner as I am working on other projects (including building a blacksmiths shop at the bottom of the garden). However, I could not resist a trip out yesterday to pick up these ECL lamps. Obviously, the glasses and burners are missing but I have a feeling there should also be brass cups in the generators to hold the calcium carbide. Without brass cups I think the alkali solution of calcium hydroxide would eat through the aluminium quite quickly. Does anyone else have the same model of lamp and would be willing to take photog
  2. Virtually all of my casting work is done by Andy of AJD Foundries. I can get there from work during my lunch breaks and I have been really impressed with the quality of work. The water manifolds have turned out well; the foundry seemed quite happy with the 3D printed patterns so I can continue to use the printer for the smaller patterns and details on the larger ones. The pipe bend for the radiator outlet also looks good. When I have finished the patterns for the radiator and made the patterns for the water pump there will be somewhere to fit it.
  3. Thanks for the kind comments on this project. It is a lovely little lorry to drive, managing quite a high top speed, pretty light steering and clutch, fairly good brakes and half decent visibility with reasonable weather protection . The Aster engine is half the power of the engine originally fitted so you get the fun of changing down at least one gear for every hill; at least it gives good miles to the gallon (more than 10). When I started putting the Dennis projects together I was working out of prefabricated concrete garage adjoining my end of terrace house. We looked for a house
  4. Thanks, I am based near Birmingham, my usual foundry appears to have been on holiday this week but has the advantage that I can get there in my lunch breaks. Good to know there are others out there. Not too much progress on this particular project this week, I have just been putting metal back onto some of the body ironwork where it has been cut or broken off. The repair pieces are being machined from EN3 steel and arc welded to the wrought iron. These ones make up the back corners of the body and carry the rear hoop.
  5. With things slowly returning to normal and a dry forecast we decided yesterday would be a good opportunity to take the lorry out for a small drive. It has not been out of the garage for six months; not at all what we had planned back in January. We emptied the petrol out last time we used it so put four gallons in the tank and it started first swing. I have added a felt seal behind the fan belt pulley since the last drive; it has slowed but not eliminated the oil leak so I will need to revisit that at some point. Another task completed recently has been the reshaping of the headlamp
  6. I think I will be visiting the foundry with a batch of patterns this week so I will check he is still happy to do aluminium and for me to give details here. The 3D printer has been used again to make the core prints for both ends of the header tank. The first step was to glue ans screw them on. Filler was used to cover the screw heads and tidy up any small gaps. The front half of the header tank pattern is now finished but I need to confirm the locations of the features on the back half. I don't have the drawings so it is being scaled from photos and chassis details but I am s
  7. Thanks, I seem to remember more of my schoolboy french than I thought as I can understand a quite a bit of that without google translate. The Solex is really well documented so once I have confirmed the bore and stroke it should be quite easy to set the carburettor up correctly.
  8. Yesterday morning we had a drive down to Somerset; setting off early to avoid the queue of caravans heading south now they are allowed to stay over night. We spent five hours picking through piles of cart and carriage ironwork in an attempt to find all the remaining parts from the long dismantled Lyons tea van. It was moderately successful as we came back with a boot full of iron for this and some other projects. Am I a rustaholic, or do I just think I am? Anyway, it is not a complete set so I will continue to build my blacksmiths shop. During the week I drilled the two h
  9. Thanks for all the help with the WO stamping. Looking through the parts book it would appear the Thornycroft T4 was fitted with a Solex carburettor (there is no text to say that but I don't think there were any carburettors that looked similar). After a little bit of research it would appear that one from 1914 should have a barrel throttle rather than a butterfly. There was one on eBay last week the right size for the Coventry Simplex engine so I bid on it. It does not seem anyone else is really looking for one as it cost me a little over 10 pounds which seems cheap for an Edwardian
  10. These patterns have been given a couple of coats of paint and will need polishing when the patterncoat has hardened. I have added 3mm of ply to each stack of MDF for the header tank pattern to make up the thickness. I then drilled holes for dowels to line the two halves up.
  11. Before the rain set in today we were able to unload the generating set from the trailer. Whilst applying plusgas everywhere I came across these stampings of the broad arrow with WO. Obviously I have seen this with WD on many occasions but I am sure someone on HMVF can explain the why this was stamped WO instead. The rocker cover has four Rotherhams of Coventry flip top oilers but only one has the lid so I was concerned the rocker chamber might be full of rust. To my surprise the oil I applied last week seems to have done the job and I was able to loosen the thumb knob that secures t
  12. Thanks Andy, Perhaps I am better off not knowing the hammer price but I am quite happy with my purchase. Although it is obvious the engine has spent some time outside and there were two spark plugs missing when we picked it up I did take some modern technology with me. The first tool was a welding rod, I poked it into the sump and to my amazement all that came out on the rod was clean, clear engine oil. No black burnt sludge, water, emulsion or rust. That might still be in the bottom of the sump but decided it was a positive sign. The second tool was a £20 boroscope. I poked thi
  13. From the same location as the Coventry Simplex I picked up this photo taken in Cologne, 1919
  14. It has been quite slow finding parts for the Thornycroft with the three major missing components being the steering box, engine and gearbox. I spotted this generating set online and we have been out today to collect it. At first I thought it was one of the Thornycroft T4 generators. The engine is very similar but in fact this one was made by Coventry Simplex. Looking at the engine numbers used in cars I think this dates it to around 1914 and makes it the 18.5hp model. I believe these generators were used to power searchlights, it ended up on a farm but from so
  15. We are still mainly concentrating on other (long neglected building) projects but really enjoying getting back into this one after so long. I have glued each additional layer of MDF onto the CNC cut templates and used the router to trim them with a slight offset to give 2 degrees of draft angle. Each is currently at 4 layers of 12mm and the final depth needs to be 4" so I need to add some thin ply or similar to the backs to finish them off. There are still a few more parts to print before moving on to the core box. The outlet is on the side of the radiator so a tight be
  16. Yesterday we printed the first half of the core box for the water connectors whilst I was working on other projects. The pattern had a couple of coats of bondaprimer and some rubbing back during the week and is starting to look good. The first half of the core box has had a light sanding and a coat of primer; the second half is hot off the printer.
  17. When I was having MDF shapes CNC machined for patterns some time ago (for the 1914 Dennis) we managed to fit in a couple of profiles for the header tank into the sheet (but not a complete set for the pattern). I have quite a bit of MDF left over from the mock cab I built (also for the 1914 Dennis) so I have cuts some pieces out a little larger than the templates. After making a couple of aluminium top hat pillars to pass through them (tapped M6 to help extract the pattern from the sand) I glued a couple of them together on the table in my office (as that is reasonably flat and will not upset t
  18. I picked up a free sample bag of threaded inserts at a engineering trade show and have been using those in the back of smaller patterns. I decided to print little handles to fit to M4 set screws as well. The project is not so much of a rush that I need to get something printed every day so I am printing small items in the evening and get a couple of the larger parts at the weekend. I am using a relatively small layer height (0.15mm) and thick walls so could print faster with thicker layers.
  19. Yes, they were from Ben. I need to organise a trip to see the Fowler next time I have an excuse to be in that area.
  20. We refitted a lineshaft to our kitchen last weekend; currently it is just ornamental and there are no plans for a flat belt driven apple lathe or mixer but I like to keep option open.
  21. I have made a few BS190 bolts and slotted nuts to secure the steering box this week, once painted I will fit them. So far I do not have the confidence to leave the 3D printer going when I am out of the house but some more of the radiator pattern parts are finished. I need to get the router out to shape the bits of MDF but we hired a skip this week so I have been moving large rocks and soil and every opportunity. Three of the water connections between the cylinder blocks are corroded away or broken. I made a CAD model of the pattern and core box. The pattern took around 13
  22. The pig was a test print. I think the castings, tube plates and tube will cost more coins than it can hold.
  23. This week I purchased a set of patterns for the Austin generating set cylinder blocks. These blocks were also used on the early (1910-1912) Austin 10hp car. There is frost damage to my blocks but they are probably repairable (as the engine runs I doubt they are cracked through to the bores). It seemed too good an opportunity to pass up and they are a great example of pattern making. Front half of the cylinder block. There are lots of core prints for the cylinders and water jacket. Note the loose pieces to make up the flange held in place with bent nails. The sand will be built up over the
  24. Thanks, I missed this at the time you posted it. Another interesting project.
  25. There is still some detailing to do on the gearbox before I can consider making any more parts. I have decided that the priority tasks should be getting the steering and handbrake linked up to make it easier and safer to roll the chassis in and out of the garage. The top of the steering box needs to be fixed to the dash. Although I started fitting the dash over a decade ago I left it 2" tall and didn't finish the dash irons as most other commercial vehicle engines would sit higher in the chassis. Now the project has the correct engine (thanks to Hedd and Ken!) I was able to finish the das
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