10-Cwt.. 2 Wheeled 5kv Generator Trailer restoration....Rebuild!

[Jerryjeeprichard]

Trailer progressing slowly. 
Full day stripping smaller component parts and degreasing in readiness for sandblasting. 
 

 

[Jerryjeeprichard]

It’s been a few months, to many other distractions. Managed to get a few days in the workshop, thought I would finish off few part completed projects. 
 

Lockers for the gen trailer now all fabricated. Just need to drill the frames ready for riveting. Then I can get the tin work cropped out and folded up. 

Few before and after pictures. Not a lot left of the originals. 

 

[Jerryjeeprichard]

Progress update. 
 

Had an afternoon of building up wheel hubs with new bearings and tow hitches, which will be used on the gen trailer. 
 

 

[Jerryjeeprichard]

Bulk of the last two days has been spent working on the gen trailer chassis getting it prepared for sandblasting. 
I’ve had to temporarily rebuild some of the engine so I could mount the engine back in the frame while I locate and fit the engine mounts 

Then lots of welding to get all the frame floor strengthened back as the original. 
 

Engine is that heavy it was easer to tip the chassis over and leave the engine on the floor. 
 

 

Edited May 7, 2023 by Jerryjeeprichard

[Jerryjeeprichard]

Help needed. 
 

I’ve started to look at some of the jobs ive  been putting to the back of my mind. 
 

One of these is the petrol tank is poor shape. 
 

Questions I have….
Any one have a good tank available. 
Do I have the one I have repaired? Anyone with recommendation as to companies that can do this? 
Or would it be easer to have a new tank made? Again any recommendations? 
 

[Jerryjeeprichard]

Todays Progress, 

Parts back from the blaster, push to get everything in primer before a change in weather. 
 

 

[Jerryjeeprichard]

Last few days progress, blasting, priming and top coating all the little nuts, bolts, brackets etc.

Now ready to start the rebuild, hopefully get this to rolling chassis over the next few weeks,

Unfortunately not many pictures but some of the springs and sub frame going on. 
 

 

[Rangie]

It really is one of the strangest of suspension/chassis layouts i've seen! 

But it does look to keep the CoG nice and low without an axle beam there 👍

Alec.

[Jerryjeeprichard]

Hi Alec 

 

Clever design really. Centre of gravity is perfect, so easy to manoeuvre around. 

 

I was surprised when I lifted the engine out how heavy it was. You wouldn’t think so pushing it about. 

[Jerryjeeprichard]

Progress report from the last few days. 

[OzH]

That does look good with all new hardware, brake pads and all... great work!

[Rangie]

On 5/29/2023 at 11:21 PM, Jerryjeeprichard said:

Clever design really. Centre of gravity is perfect, so easy to manoeuvre around. 

Fascinating! I see the "bogey"/axle for want of a better term is located by the leaf springs and has a friction damper in each corner, but are there any other "stays" or pivot arms to keep things central? It's a cunning design.

I can see that its effectively a square-surrounded/centerless beam axle but its still a little brain-bender 🤣

Alec.

[Jerryjeeprichard]

Hi Alec, 

There is a torsion bar at the front. 
 

You can just about make it out on the photo attached. 
 

 

[Jerryjeeprichard]

Todays progress. 
 

 

[Jerryjeeprichard]

Pushed the generator trailer on a little today. New sheet metal for the stowage bins. 
 

 

[Jerryjeeprichard]

Weekend spent fitting the new tin work on the wheel lockers. 
 

Hours of drilling, quite pleased with the end results.
Bolted them together for now, eventually I’ll need to pull them apart, few small repairs on the arched sections needed, paint, then ready to rivet them back together. Just need to work out a method. 
 

 

[Jerryjeeprichard]

Bit more progress on the trailer. 
 

Bins temporarily sat back on now ready for riveting. 
 

 

[Jerryjeeprichard]

Started to look at restoring some of the smaller parts.
 

One of the jobs I’ve been putting off is the Carb and exhaust manifold. It’s in a very sorry state, getting it apart without cracking was a challenge. 
 

 

[Jerryjeeprichard]

Bit of progress over the last few evenings. 

Thinks turned out better than expected.. 

 

Still a little bit of work left to complete. Manly internals on the carb. 
 

 

[Jerryjeeprichard]

Thought I would share a few original images of the 5kv generator trailer. 
 

Looks like these little trailers would have been fitted with different power packs. 
 

 

[Jerryjeeprichard]

Started today rebuilding some of the upper panelling for the gen trailer. Few before and after pictures.
 

 

[Jerryjeeprichard]

Day 2 of panel building. 
 

Just don’t know where the hours go. 
 

 

[Jerryjeeprichard]

Few hours today on the steel work for the gen trailer. 
 

Weirdly the grill has been one of them jobs I’ve been looking forward to fabricating. 
 

And yes the grill is short compared to the surround before anyone points this out,  
 

 

 

[welbike]

Only just saw and read all of this thread, interesting they used a US Waukesha engine! It might not be known to you that the FC series engines were also used in the Clark CA-1 Airdozer, follow my resto here: 

 

I have a UK source for headgaskets, and some US sources for other parts, but it aint easy! Check cylinder head for cracks, as they are usually cracked along the top. (see picture) 

Also some other engine info.

Cheers,

Lex

FC_04-42-r specs.pdf FC151E engine specs.pdf

[Jerryjeeprichard]

Lex. 
 

I’ve read your post end to end on the Clark, challenging restoration. But very rewarding. 
 

Head wise mine has blasted up well, no cracks fortunately. 
 

I’m in the need of valves and piston rings and a good sump. Once I have these I can maybe make a start on rebuilding the engine. 
 

Have you any good leads for parts? 
 

Engine manuals gratefully received too.
 

Richard