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Everything posted by BenHawkins

  1. 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
  2. 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.
  3. 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.
  4. 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.
  5. 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
  6. The pig was a test print. I think the castings, tube plates and tube will cost more coins than it can hold.
  7. 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
  8. Thanks, I missed this at the time you posted it. Another interesting project.
  9. 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
  10. The later gearboxes are stub tooth 5dp 20 degree pressure angle. The original was 6dp 14.5 degree pressure angle; shafts, covers etc. are all different but I may be able to use some of the transmission brake parts.
  11. The ratchet detail is one of the drawings that survives. The tip angle of the pawl is 77 degrees and therefore I expected them to lock in when the hub is being driven.
  12. I have a couple of 1920s Dennis gearboxes I could fit but I would prefer to put the correct version in. It is probably too much to hope that the correct gearbox will turn up so my only option will be to manufacture one. I don't like the idea of paying someone to have all the fun even if I was able afford it. I have made a few of the simple components already but it is certainly going to be a challenging project.
  13. We have been tidying the garage so we can get back into this project soon. I have been working through the information I have found on the gearbox and started to model it in CAD. There are 39 parts listed in the catalogue but there are no diagrams and it does not list things like bolts, keys and taper pins. Drawings have survived for 14 of the components; this includes the four shafts but does not include the selector rods or gears. Much of this detail can be guessed at from the drawings in the patent. One of the novel features is the freewheel mechanism. What force do you
  14. We decided to have afternoon tea with the working vehicles to celebrate VE day; this was the second drive for the 1908 Singer but as it is only 15 metres between the garages it really needs a run out on the road to get a better idea of the performance. Tinkering has continued on the Dennis and we have added a felt seal to the back of the fan pulley as it leaked a fair bit of oil. If a road test shows it to be relatively leak free I can swap the modern belts over to Whittle belts. I have also found a Powell and Hanmer self generating headlamp (as shown in the in-service photo) but it
  15. I have blasted the ironwork and really liked how the blacksmith tidied up the corner by forge welding a triangular piece in. They have cleaned up well. Repairing the threads that have been cut off will have to wait for a later date. I briefly looked at how much it would cost to reproduce the body in oak as used originally. Some shopping around will certainly be required.
  16. This project has been on hold for too long, we hope to restart it later this year. The current project is a 1908 Singer (I could not come up with even a tenuous link to military for that one). I had one of the wheels rebuilt by an excellent wheelwright; he brought me a present for this Dennis along with the Singer wheel. Back in 1976 he rescued a dilapidated horse van that appears to have been identical to those used by Carter Paterson and as originally repurposed to the body for this 1908 Dennis project. The four parts are (top to bottom): 1. Shore Staff 2. Timber Sta
  17. I have photos on the day it left the factory and one in service and none of them show anywhere to tie ropes.
  18. In order to rectify a slight coolant leak I removed the water pump to add more gland packing. Whilst the coolant was drained and the pump was off I machined a boss, silver soldered it to the coolant pipe that feeds the cylinders, then drilled through and tapped it 1/4" BSP for a tap. This was in preparation for providing water heating to the carburettor.
  19. Thanks for the kind comments about this project. Looking at your lovely photo of KT665 it is a very similar age of lorry and could either be identical to mine or possibly the 30cwt version. The three ton did not have the offset in the front axle (outboard of the springs) so the chassis was a few inches higher up. Coincidentally I have been building a machine on this slightly lighter road rail trailer recently so the concept is not completely dead. The two ton lorry was fitted with 720mm wheels for 100mm wide tyres. I have include a PDF of the tyres to show the dimen
  20. Steering column detail showing worm and nut steering box. A selection of parts. Many of these I have, but it is good to have detail of the front cross member. Bonnet rest etc. And finally the radiator, this appears to show that I have the correct radiator. Although pretty good this parts book still appears to miss quite a few parts such as the exhaust silencer. Period literature described the T4 as a "J type in miniature"; although this might be true for the chassis construction there are many differences in the rest of the
  21. Front Axle. At least I have most of these parts. I think this shape of axle cap (Part number 55312) is only seen on the T4 Thornycroft. The back axle built up in three layers is another feature that seems unique to the T4. A sliding block rear universal joint is used. I am missing this but as it is similar to the one I made on the 1914 Dennis at least I have had some practice. Brake drums and blocks.
  22. Gearbox. The N/S and O/S gearbox mountings look identical in the photo but have different part numbers. And quite a few parts to go inside the gearbox. Footbrake components And some of the parts on the outside of the gearbox
  23. And for me, this is where is gets most interesting. Parts diagram showing the cylinder block with fixed head and inlet over exhaust valve arrangement. Crankshaft, camshaft, oil pump etc. Oil pipes, magneto couplings etc. Flywheel, clutch etc. This does not show the fan blades on the flywheel (visible on earlier photo).
  24. Flywheel, clutch and universal joints. Gearbox, steering gear and brakes. Care of the back axle Side view of chassis
  25. Some good pictures of the T4 engine; perhaps somebody has one in their shed. Further information on the engine and some good views of the crankcase. A little information on fault finding A good view of the steering column detail, fuel tank and oil indicator.
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