DAN THE STEAM

Hi all, heres another piece of the story, i have now finished the steering box pattern after starting it just before christmas.

1. Side view showing the bolting face for chassis.

2. Showing both halfs split.

3.Inside face with side plate flange and core print.

4. View looking from the back showing the part that took some problem solving .

5. View of the front .

6. View showing two removible lugs that form the back stop bolt face also showing the core box built on one half of the pattern which the sand can be molded in to form a print due to the complex shape.

7. Showing the two lugs removed, this enables the sand core to be removed from the core box, when the core box is removed from the pattern the sand core will be put back to the pattern and then molded with the pattern to form the flange and the bolting lugs plus the core print for the side.

8. View showing all the parts of the pattern with all five core boxes, side and inside cores also showing the side plate casting and the steering colum base pattern.

I am hoping to get to the foundry this week, cant wait.

I hope this makes sense.

Dan and Jen.

Hi all, sorry about long delay in posting, thank you everyone for there kind compliments and also for helping in the quest of finding parts.

I have been working on the steering box pattern almost finished now plus also making the patterns for the steering colum and side plate for the steering box, i havent started the internals of the box yet as i will try to finish the patterns first, i will post some pictures of these when i finish them.

I have now fitted the radiator to the chassis and also made the bonnet frame that goes on the bulkhead to support the bonnet, heres some pictures.

Dan and Jen

Hi all, thankyou for all your kind compliments i enjoy what i do and if i can give other people enjoyment aswell then its worth it, iv been working on the rad again and apart from a filler cap she is finished that is one more drawing folded away heres some pics.regards DAN and JEN.

Hi all, jen and i have been working on the radiator core today which started from index drilling the tubeplates (brass now not ply) to fitting all the tubes in the bottom tube plate first, that was the easy one then alinging the top tubes that took a bit longer but got there.These pictures are to show how clean the soldering is.

Regards Dan and Jen.

Hi David, the plywood one was stronger than the cardboard one as an econamy fit :cheesy: but Geepig does have a good point short term anti leak system.

Here are the pedal pics as promised Regards Dan and Jen.

Hi all, sorry about the long wait, i have been working on the Halley's radiator header and bottom tank, i was going to make patterns for them and get them cast but the amount of time this would have taken i thought i could fabicate them and finish them off to look just like castings also building in machining alowance for distortion that over the total length i managed to keep it within 1/8th of an inch on the machining faces.

Both parts have been machined and index drilled for the tube plates and all the flange mounts have been machined true to the base so that the pipe fittings bolt up nice and level to the rest of the radiator, i finished all this last week and was started to panic about what to do about the core and then on friday a freind popped in by chance to see what was in the works, and whelst talking to him and showing the radiator he said he had a pile of new old stock radiator tubes in his atic so after he mesured them on friday eve he said yes to a visit on sat morining that we did and i bought 160 of them, i have since cut down and removed 3/4 of an inch of the giles from the sawn down end and put them into some plywood to see how thay look and now the Halley has a face:yay: :yay:and a brand new radiator made to one hundred plus years works drawing. The back of the rad showing the first row being fitted.

Have also machined and fitted the foot tread castings will post pics when i get them enjoy.

DAN AND JEN.

Happy christmas Tony Steve and all the family, the first ball joint was machined free hand and took me all day to machine the one ball and the shank, also the same for the cups so i then ground up a tool for machining the sockets then lapping them into the balls with paste. The ball was a bit more tricky in the end i dismantled the compound slide and bolted a rotary table to the sadle on the lathe then fixed my cutting tool to the table, so i could machine the ball round and it worked really well. I have fully machined two am machining a therd now and started the forth and have also started the track rod as well. The next machining chalenge is the steering box :shake:.

Happy christmas all and a happy new year from Dan Jen and the Halley

Happy christmas David, i did not think i would have to machine them neither very time comsuming but so proud of them.

Happy christmas from Dan Jen & the Halley.

Hi all, some more pics of progress on the machining of the track rod ends. DAN AND JEN

Heres some more pics of the new castingsDan and Jen.

Hi Rod, i also look forward to the day i can drive her on the road thanks.

Heres some more pics enjoy.

Hi Ian201, sorry about that i hope you got back without two many problems with the landie, also your more than welcome to run your camra over the matador when your ready if theres any pics you need in until then just let use know.

More halley parts to come.

Dan and Jen.

I'M BACK!:wave: Hi all, sorry I havent posted for some time now I have still been working on the Halley as well as other projects and jobs.

Today i went to the foundrie to collect the radiator side castings and the patterns and also the steering joint castings plus pattern, i have also made the new mudgaurd brackets for the front end plus finishing off the front axle, shackel pins, and the new front hooks so all now fitted so heres some pics of the patterns and will post pics of the castings at some point.Dan and Jen.

Hi Ian, im looking at my options on making a pattern for the stearing box casting so prob yes to having it cast just need to save up for it.

DAN AND JEN.

Hi Ian, thanks i cant wait to see your mat when shes done will let you know when your hoopsticks are done.

regards Dan Jen and Joe.

Thankyou Shane.

Hi mtskull, thanks i do my best and i can't wait for the day i can drive the Halley.

Hi all, got into work early to fit front axle, so now i have one W D Halley rolling chassis.:yay::yay::yay::yay::yay::yay::yay::yay::yay::banana::banana::banana::wave::wave:

NEXTJOB to make the stearing arms balljoints and trackrod, and then look at starting the stearingbox, i have got a stearing box that was kindly given to me by Tony and Steve gosling (thankyou) its not a halley box but i will try to use the internals out of it and fab my own casing.

DAN AND JEN.

Hi all, here are some pics of the axle after machining more parts for it enjoy. DAN AND JEN.

Heres some more for you all to see.DAN AND JEN.

Hi all, i have now pressed the bronze bushes into the guide tubes and pressed the tubes into the axle and also screwcut the caps. Enjoy DAN AND JEN

Ian this one is for you, this is what dad's matador looks like so far after having the new canvas from Martin at allied forces

fitted. The next job is to fit the front seat box.This is what your mat could look like.

regards DAN AND JEN

Hi Steve, its taking longer than id like it to but is getting and im pleased with the results, heres some pics of the bearing tubes for the front axle.Regards DAN AND JEN.

The front axle after the machining and making of the U bolts.DAN AND JEN.

Hello Old School Punk, thanks I aim to get the highest standard I can get in the work I do, and I also get joy from inspirering other people to do there projects.

Keep following this as there will be alot more to see.

Thanks DAN AND JEN.