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8 minutes ago, PITT24423 said:

Cheers Thomo, this casting is pretty poor on the coolant side which we have blasted several times with it sweeting after each occasion lifting off another layer each time .Leaving us two options two pack epoxy which we have successfully used before or cast new. The problem we have is that the local non ferrous foundries are not interested in one offs. We might of got it sorted by calling in a favour before we go traipsing across the country.so we will wait and see.

 

7 minutes ago, PITT24423 said:

Cheers Thomo, this casting is pretty poor on the coolant side which we have blasted several times with it sweeting after each occasion lifting off another layer each time .Leaving us two options two pack epoxy which we have successfully used before or cast new. The problem we have is that the local non ferrous foundries are not interested in one offs. We might of got it sorted by calling in a favour before we go traipsing across the country.so we will wait and see.

2 pack fillers are no good on radiator tanks. Ask Steve Gosling.  Tomo (no h !)

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Photo opportunity moved the body this evening over to our main workshop as this is the first Saturday we are not working so I can fit the top deck handrails.Paint is nearly there with a couple more co

Top deck seats finally finished and fitted, can’t believe how many hours they have collectively taken , just about all of us are seated out !  Felt seals turned up for the king pins and front wheels

Got stuck in to the body most evenings and the last couple of weekends which we now feel we breaking the back of it .Ali bulkhead was rotten so a copy was made ,this was screwed plus I bonded on with

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On 12/14/2020 at 7:45 AM, PITT24423 said:

Gearbox all stripped and cleaned large amount of road grit which presumably entered the box through the broken casing which has resulted in all the bearings being unserviceable. All the original bearings are Hoffman who were based in Chelmsford where as the bearings in the lorry were Swiss . New bearings are all on order and due in this week. We will do the same as we did with the lorry and fit double lip seals with the minimum of modification as I personally prefer to have things as oil tight as possible in our environmental sensitive world.

After numerous under coats the wheels have gained their first top coat which in my opinion has changed their visual size and appearance for the better.

 

Hoffman Bearings must have been a pretty big company and were used in many high class vehicles.  My 1929 Rolls Royce 20/25hp. has Hoffman bearings throughout.  This is the outer left front wheel bearing.  Not too sure what I will be replacing them with at this stage. 

 

 

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21 minutes ago, Tomo.T said:

 

2 pack fillers are no good on radiator tanks. Ask Steve Gosling.  Tomo (no h !)

True if you use tap water only or a average antifreeze. Shuttleworth were (maybe still) using a Honda coolant in the aircraft because of the inhibitors and I know others use deionised water which is why I choose to use the waterless coolant as it ticks all boxes with no expiry date. The problem with it is that it finds the slightest hole or crack which more often than not wouldn’t leak with conventional coolant , so you need to be water tight from the off.

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1 hour ago, Citroman said:

Here just over the border at the Aachen technical university they can 3D-print metal. No one like that in your area?

You can order 3D printed aluminium online. But it's horribly expensive:

https://www.shapeways.com/materials

I looked at having an inlet manifold for a motorcycle cast, and it would have been £1200. 

However, I think that the main part of the cost is the overall volume (and especially height) so the pump parts might be worth investigating. 

 

3D printing a pattern for conventional foundry casting is probably worth considering, though. 

 

We have a couple of Aluminium printers at work, but sadly I have not found a way to sneak my parts on to them. 

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Foundry located inNorfolk who are going to cast the pump casting and the radiator side castings in the new year.

Gearbox bearings and seals arrived so I can think about getting the box back together over Christmas .

Back axle stripped and blasted so I can start getting “ diff “ inspiration hopefully scheming something out of what oily lumps of diffs we have accumulated.

Repro nuts and bolts arrived caught me out how long it took to swap with the temporary bolts. 
Fuel tank fittings freed off and cleaned, realised the fuel cap had been repurposed to the Kiwi made gearbox top. Luckily we have spare gearbox caps as they are the same as the diff oil level cap . The tank is away now being acid cleaned as it looks as if it has had its share of H2O .Apart from the newness hard to tell the difference between the rivet bolts and rivets.

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Chassis given a few coats of top coat in between festive eating and drinking. Body jacked up and trolley removed ready for chassis marriage tomorrow , all of a sudden it looks a bit on the tall side. In theory it’s about 3” higher on the stands than it will be on the chassis for real minus a bit for spring compression.
 

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Nothing spectacular to report other than lots of loose ends to tidy up. Seat backs retaining straps folded up and painted. Drivers steps fabricated and fitted. Drivers floor frame made to determine pedal positions.

Started to set out seat box with limited information available. Cracking photo in Bill Wards book of Daimler bus bodies laid up for the duration of the Great War .A bit of polishing has gone on under the bonnet.

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Rear springs fitted with new bushes and pins which were made oversized so we reamed the shackles and hangers to save making sleeves . Rear axle fitted and brake actuators which were stripped and cleaned earlier refitted.Started to set out staircase and will be a combination of templates from a restored B type and a London General Omnibus drawing we have which is so close to the Birch Brothers body we have . We were lucky in the fact all six of the original electric light fittings survived but unfortunately none of the glass lenses. A friend had some almost identical but the lenses are a fraction larger . I have now found a company who can replicate them to the required size but still have to find someone to cut the star in the bottom. We now know this is a early body which was lit by gas (carbide) and converted probably around WW1 to electrickery. We are now looking for a Lucas electric conversion for the oil lamps which was a bulb holder which screwed in place of the red lens in the back of the lamp.I’ve had these lamps on the shelf waiting for a permanent home for over twenty years which are probably originally for a car  being a single spade whereas we should have a fork fitting but it is a case of I have them and they are complete.

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Top deck seats finally finished and fitted, can’t believe how many hours they have collectively taken , just about all of us are seated out ! 
Felt seals turned up for the king pins and front wheels. Rear wheels,we will machine out the felt seal carrier to take a lip seal as this has proved successful in the lorry and a unseen mod .The brake shoes are away being relined with a superior lining matched to the drums so hopefully the brakes will perform better than ever once bedded in.
Stair set out and pattern stringers cut out of 4mm mdf to double check all is well. Simon drew up what we had created with additional radius’s to replicate the drawings we had as a dxf file for both stringers and will get lazer cut later this week out of probably 18g where as originally we think they were 20g . Reason for increasing the thickness is to improve strength as everyone appears bigger than their ancestor .

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Thanks for the previous two posts of help but fingers crossed i may have this one covered now as theres a resident old bouy engraver at the other end of the island who has hopefully going to engrave the lenses for me .Plan B i`ve got some spare lenses being blown to cover all bases if the worse was to happen .

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A bit of luck as a correct period Hackney carriage plate was flagged up to me on our favourite auction website These plates were issued to buses until the 30’s by the Met Police in a similar manor as they still are today for taxis. Apparently the crown alternated yearly with the unicorn and lion crest. 
If anyone  can add or knows if any of above is incorrect please let me know and I’ll correct the text, thanks.

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Borrowed a former from a friend which I adapted to make the rear mudguards which we successfully glued up three layers of 4mm ply this afternoon with the proof being tomorrow when we release all the clamps.Will glue up the second mudguard later during the week . A bit more luck in that another friend unearthed a pair of headlamps which arrived this week which share a close resemblance to the ones originally fitted to CBs 

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