Minesweeper Posted March 13, 2010 Share Posted March 13, 2010 The porosity in the small bolting flange is annoying but not the end of the world. I shall make up the small flange with its pipe that bolts on to it, just to see exactly where the bolting holes are going to come - and then plan how to deal with the porous bit. It may well be that the easiest solution is to drill or mill out the porous bit and replace it with a piece of bronze rod - either to screw it or silver solder in. I think that it will become apparent as I proceed. Tony Quote Link to comment Share on other sites More sharing options...
abn deuce Posted March 13, 2010 Share Posted March 13, 2010 I guess that will depend on how big the void turns out to be . Quote Link to comment Share on other sites More sharing options...
Minesweeper Posted March 13, 2010 Share Posted March 13, 2010 I guess that will depend on how big the void turns out to be . Yes, I think so. I have pushed a bit of wire into the hole and find that it is as deep as 3/8" in one place - but it seems to taper inwards and does not go right through the casting - so I remain optimistic that it is nothing that cannot be put right! Tony Quote Link to comment Share on other sites More sharing options...
Gordon_M Posted March 14, 2010 Share Posted March 14, 2010 I'd be brazing that up. I think I'd braze it before I opened up the main bore too. Gordon Quote Link to comment Share on other sites More sharing options...
Great War truck Posted March 15, 2010 Author Share Posted March 15, 2010 Tony made up the embryo flange which will hold the smaller water pipe to the elbow - just so that he could see where the holes are going to come on the elbow - bearing in mind the porosity that we have found. No problem then apparent that could not be overcome. Drilled out the porosity in the small flange - diameter 1/2" - turned a plug from cast gun metal and silver soldered it into the hole. Cleaned up the dirtiness on the elbow after the brazing - then reset the elbow in the milling machine and machined the surface back again. The elbow now ready for further work to complete it. We hope that the bulk of the porosity has now been taken out and it will be interesting to see if any more appears when the three holes are drilled into that small flange! Quote Link to comment Share on other sites More sharing options...
Great War truck Posted March 16, 2010 Author Share Posted March 16, 2010 Another productive day. Tony marked out and drilled the three fixing holes in the Elbow first of all and then used those to locate the corresponding holes on the cover. Drilled out the holes in the cover and tapped them 3/8"BSF. Opened up the holes in the Elbow for clearance for the Stainless Steel Bolts made earlier and married the Elbow and the cover together. He then put the three holes in the small bolting face of the Elbow for the smaller copper pipe to the Inlet Manifold - the throat on the Milling Machine and on the Pillar Drill are not big enough to take the Elbow in a vertical position - so he set it up on the Cross-slide of the lathe and drilled the three holes that way - the two smaller holes to be tapped out to 1/4"BSF and the larger hole to 1/2" for the water passage. There were obviously more problems around that area of the flange with porosity and also possibly inclusions as the noise the drill was making and the vibrations coming from it during the operation were significant, but he seems to have drilled all of those out and fortunately was left with clean surfaces. The little flange to take the copper pipe is still to be finished - it has to have a 7/8" boss on it into which the copper pipe is soldered and that will be tomorrow's job. Getting near the end of this Pump construction and final assembly of all the components now very shortly.. Quote Link to comment Share on other sites More sharing options...
AndyFowler Posted March 16, 2010 Share Posted March 16, 2010 Lovely job as usual mate , I wish I had the skills you have ! It would appear that you can make anything you wish ! :-D Quote Link to comment Share on other sites More sharing options...
Old Bill Posted March 16, 2010 Share Posted March 16, 2010 Lovely job as usual mate , I wish I had the skills you have ! It would appear that you can make anything you wish ! :-D Thanks for your compliments Andy. We are very fortunate in the skills we share but I am absolutely convinced that anyone can do it if they want to enough. Just buy a book and have a go! That's how Dad started it all. I am currently reading up on blacksmithing. There are several brackets on the bodywork which will require hand forging and rather than pay someone to do it, I want to do it myself. You will undoubtably see the results in due course and be able to have a laugh at my efforts. That's fine. Hopefully, I will get better with practice! Steve Quote Link to comment Share on other sites More sharing options...
AndyFowler Posted March 16, 2010 Share Posted March 16, 2010 Very true mate , you are a very good team of craftsmen ! Just wish you lived next door ! :-D Quote Link to comment Share on other sites More sharing options...
Great War truck Posted March 17, 2010 Author Share Posted March 17, 2010 A little bit more done little today - Tony finished off the flange to take the Inlet Manifold water pipe. The pictures of the method didn't come out very well but the four attached should be self explanatory. The two bits of brass were silver soldered together and a 15mm hole drilled in the assembly afterwards to take standard 15mm copper pipe. Quote Link to comment Share on other sites More sharing options...
Stormin Posted March 18, 2010 Share Posted March 18, 2010 The two bits of brass were silver soldered together and a 15mm hole drilled in the assembly afterwards to take standard 15mm copper pipe. :shocked: :shocked: :shocked: 15mm copper pipe? Surely you'll be getting imperial pipe and not metric! Quote Link to comment Share on other sites More sharing options...
Old Bill Posted March 18, 2010 Share Posted March 18, 2010 Yes, well it should be 9/16" (0.5625" dia) but the 15mm (0.591" dia) is in stock and I don't suppose anyone will notice. Steve Quote Link to comment Share on other sites More sharing options...
Great War truck Posted March 19, 2010 Author Share Posted March 19, 2010 Productive day today. Tony drilled and tapped the Pump Body 1/4"BSP for the Drainage Tap. Straight forward and no problem. Had to hold the Pump Body on the cross slide of the lathe again to drill it because of insufficient clearance in the Milling Machine and Drill. Time now to attach the Pump Body to the Pump mount - the parts were first of all offered up to the lorry so that he locate the Body on the Mount so that the top pipe flange would be horizontal - or parallel with the line of the engine.. Also an opportunity to see how the pipe to the bottom of the radiator and to the inlet manifold would line up. Holes now drilled into the pump body to hold to the mounting - lined up from the previously drilled pilot holes in the mounting - then opened up and tapped 3/8"BSF - using previously made stainless steel bolts to fix the two together. Pilot holes in the mounting then opened up for clearance of the 3/8" bolts The job is now mainly done - perhaps tomorrow before the Rugby starts, he will locate the cover where we want it and drill through from pilot holes already placed in that to fix the cover to the body. As you can imagine, the whole unit is quite a weight - hope the engine is man enough to hold it! Quote Link to comment Share on other sites More sharing options...
Gordon_M Posted March 20, 2010 Share Posted March 20, 2010 Lovely work, as usual. The problem with all these ' one-offs ' is that to get the machining dimensions and know you have a usable end product you are going to end up making everything out of a slightly heavier section casting than the original. I'll bet the original production unit would be upwards of 20% lighter than your new one and consequently a lot lighter. Like me part of your casting coat will be the casting material weight, as that stuff isn't cheap, or light. ( I got some gunmetal bronze brackets cast for my DUKW and Weasel compass mounts, 2 Kg per bracket, or should I say four and a half pounds ...?) Gordon Quote Link to comment Share on other sites More sharing options...
Old Bill Posted March 20, 2010 Share Posted March 20, 2010 Yes, I am sure you are right. My pattern making skills are only modest and I tend to err on the side of caution so everything is a bit thicker than it need be. I guess that if we were making dozens of them I would gradually rework the patterns to use the minimum amount of metal as the cost would be an issue. For one off, I am satisfied if they simply work! Incidentally, the early pattern pumps were made of aluminium but there was much comment in the automotive press at the time about the high rate of corrosion that they suffered. They would, however, have been lighter. The first run of the engine is beginning to come over the horizon. It's all getting rather exciting! Steve Quote Link to comment Share on other sites More sharing options...
Great War truck Posted March 21, 2010 Author Share Posted March 21, 2010 Drilled and tapped the holes 1/4" BSF in the Pump Body today to hold the cover - using the previously drilled pilot holes in the cover as guides. The pilot holes were finally opened up to clearance size for the bolts. With all the main parts now made up, we are ready for a trial assembly of the whole unit. Quote Link to comment Share on other sites More sharing options...
Richard Farrant Posted March 21, 2010 Share Posted March 21, 2010 Tim, That is a work of art, well done to all of you. Not long now before you can run the engine I guess? Quote Link to comment Share on other sites More sharing options...
Minesweeper Posted March 22, 2010 Share Posted March 22, 2010 Yes, getting closer and closer to running, Richard - but one thing that we have not yet really put our minds to is the exhaust pipe! I think that we should have that on first! Tony Quote Link to comment Share on other sites More sharing options...
The Bedford Boys Posted March 22, 2010 Share Posted March 22, 2010 You don't need an exhaust pipe on to run it :cool2:.....Engines always sound good straight out the manifold. Ran a mates mini without a pipe on, sounded awesome :shocked: :nut: You guys are doing such excellent work on this machine. People say they can't wait to see the finished product, but I'm enjoying seeing how you guys tackle each problem. Keep up the astounding work! Quote Link to comment Share on other sites More sharing options...
Great War truck Posted March 22, 2010 Author Share Posted March 22, 2010 The trial assembly of the Water Pump now successfully completed and this sequence of photographs will show the procedure. Firstly, the impeller was be fitted to the shaft. Keyways have been machined but no key fitted at this preliminary trial. A bronze or copper washer needs to be made up to go under the nut. The impeller and shaft then dropped into the pump body. Next, the gland and gland nut were placed over the shaft and tightened. Then the mounting was placed over the shaft, gland and gland nut and the mounting was bolted to the pump body. Quote Link to comment Share on other sites More sharing options...
Great War truck Posted March 22, 2010 Author Share Posted March 22, 2010 Then, the pump cover was offered up to the pump body and tightened down. The front elbow was then bolted to the cover. The top elbow was then placed into position on top of the pump but this has not yet been drilled to take its fixing studs from the top flange of the pump - and neither has this yet had its studs fitted. It may be necessary to machine a slope on the bolting face of the angle to ensure that it properly lines up with the corresponding pipe fitting on top of the engine as there is a copper pipe joing the two and not a rubber pipe - so it will be essential that they come into line. The whole unit weighs in at about 30lbs. The impeller is turning freely and smoothly within the pump! Job done! Next job - to fit it to the engine. Quote Link to comment Share on other sites More sharing options...
Chrisg Posted March 22, 2010 Share Posted March 22, 2010 Nice work Quote Link to comment Share on other sites More sharing options...
Bystander Posted March 22, 2010 Share Posted March 22, 2010 Beautiful! Quote Link to comment Share on other sites More sharing options...
Great War truck Posted March 25, 2010 Author Share Posted March 25, 2010 Because i have posted so many photos I have now exceeded my Monthly photobucket bandwidth. As a result most of the photos have been disabled. They should be back by the end of the Month (or so they tell me). Sorry, but there we go. Tim Quote Link to comment Share on other sites More sharing options...
Great War truck Posted March 25, 2010 Author Share Posted March 25, 2010 OK. All of the photos should be back now. I have upgraded my account so i can upload an unlimited amount of photos each Month. Enjoy! Quote Link to comment Share on other sites More sharing options...
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