Karrier WDS

[Doc]

A quick post to describe the consolidated efforts of a few weekends back East.

Some weeks ago I started measuring up for the plug lead conduit, as I had found a supplier online who was able to supply custom  bends in 1 5/8" diameter steel tube.

Move forward a couple of weeks and the tube arrived, over length, so it was offered up again to confirm the correct size.

The eagle-eyed amongst you will notice the brackets have changed orientation. After consulting the 1977 "as found" photographs I realised that the conduit was originally fitted on the off side. 

A final check that the lengths were correct...

Next job was to make a swage block to flare the ends of the conduit.

Note: the tube has to be flared with the brackets in-situ as, after flaring, they are captive.

Next, onto the mill to drill the holes for the plug leads. "Measure twice, cut once" was the order of the day here.

Followed by a good clean and a visit to the paint shop

And, first thing this morning, back on the lorry.

Sorry for the poor quality of this photograph; it was scarcely light.

 

Doc.

 

 

[Old Bill]

Nice progress. You are getting close now!

Steve🙂

[Doc]

Seems Santa has been busy sourcing switches. I'd had the "Karrier" switch for a while but it's a bit too modern for the WDS. Fortunately the Thomson Bennett one turned up. 

This is now fitted; I had to wait for an online retailer to deliver the 5BA screws and nuts.

[alsfarms]

Nice.....one more little step in the right direction!

Al

[Doc]

I've got wood!

So, despite the grey, wet weather with which so many of us seem to be afflicted, I've managed to keep myself amused.

I started by cutting the planks for the seat box:

Then assembled, drilled and screwed together with no. 14 slotted screws.

Then the back of the box

Next, fettling the door pillars to fit before drilling the bolt holes and coach bolting into position.

Next in line was to fit the kick board around the clutch and brake pedals.

Have now started measuring up the floorboards but light is failing and the floodlights cast too many shadows so I'll pause for another day.

Doc.

[alsfarms]

Good work and a very nice way to be amused.  It might be a bit different if you were doing this project outside in the rain!

Al

Edited December 28, 2022 by alsfarms
spelling

[nz2]

Is this seat as per the original specs regards height and depth, or have you altered it to suit our larger body size for these times.  Is the seat higher, as we are taller than our earlier generations and also the cab wall has to be back a little more to allow us to fit in 

 Doug 

[Doc]

Hi Doug,

Seat dimensions are best as I can judge original. I'm certainly no taller than the previous generation. Whilst I don't recall exactly how tall my father was, his late brother joined the police at a time when you had to be over six feet tall to apply.

Regards

Doc.

[7VHU]

Serious overhead crane envy… : )

[Doc]

The Easter holidays have afforded the opportunity to head east and continue with the seat box construction.

All pretty self-explanatory:

Then off to the paint shop:

Grey undercoat applied this overcast Easter Monday.

I still have to cut the holes for the fuel filler, level gauge and dip stick. I had measured and marked the positions but will get the box up onto the chassis before I commit to cutting them.

[Minesweeper]

Very pleasing to see all of these different skills being exercised so well!

 

[Doc]

A quick update from a speeding train.

Our favourite online auction site supplied some shiny new hole saws, so I have proceeded to cut holes.

With help from my brother I lifted the seat box up onto the radial drill and clamped it to the bed. This drill was chosen for its very low drilling speeds - 20, 30 and 40 rpm. Hole positions were pilot drilled but the saw was centred using a length of 1/4" brass rod to guard against the saw wandering.

Holes for mummy bear and daddy bear were cut before the box had to be repositioned to cut the hole for ickle baby bear.

Pictures below will fill in the details:

Followed by a trip to the paint shop and a brush full of primer on the freshly cut and sanded surfaces.

I've also found time to get some primer on the floorboards.

[Doc]

Another speeding train; this is getting to be an expensive habit. Two long weekends have afforded the opportunity to get all manner of jobs done.

Karrier wise, the seat box has been placed in it's correct position on the chassis, as testified by the correspondence of the holes with their respective features on the petrol tank.

Not sure what this little chap is doing here...

After a bit of fettling the door pillars are fitting a lot better. Attention has now turned to fitting the outer rails that support the ends of the floor boards.