NSWGR Trikes wishes everyone a MERRY CHRISTMAS and a HAPPY NEW YEAR.
Monday, December 24, 2012
Saturday, December 8, 2012
Die neue Auspuffanlage angekommen
I recommend Wolfsburg Motors in St Peters, NSW if you require air cooled VW parts. Great service and the hard to get parts are no worries.
It took a 9hr round trip to pick up the new exhaust and head studs for the VW trike.
When the heads come back from reconditioning the engine can be put back together.
It took a 9hr round trip to pick up the new exhaust and head studs for the VW trike.
When the heads come back from reconditioning the engine can be put back together.
Saturday, December 1, 2012
Progress on the VW project
All is going rather well with the VW. As of this post the car is 99% dis-assembled. The chassis is ready for sandblasting.
The engine was removed first and given a blown down test. This test involved a modified spark plug to hook up compressed air to the engine. By listening in the exhaust and inlet ports for air escaping it told you if the valves were leaking or not. If air was escaping through the crankcase filler, you would know the rings were worn. Cylinders 1 and 2 inlet valves and 3 and 4 exhaust valves leaked. The heads were removed and taken to a machine shop to have the valves re done. Wickham 526 cylinder bore is also in the shop for re boring (more on that later). The clutch and the flywheel was removed, low and behold the clutch is brand new, someone put it in and never used it, still got the paint markings on it. A new flywheel seal was installed and the clutch re-assembled.
The tin ware is awaiting stripping and cleaning then to be painted and waiting on new head studs and exhaust before the engine will be re-assembled. Engine parts are plentiful for the old donk, lots of aftermarket gear available but try getting a muffler for one. The rear axle of the car is so close to the exhaust it must have a stock one fitted. A search of over 30 vendors resulting in just one being able to supply the muffler and that one still had to order it in for me.
My Father has been doing the mechanics on the VW engine, it's one of his specialities.
Many things are rusted beyond repair and had to cut off, lots of stuff will have to be rebuilt or remade. Just today the axles were taken off and the gearbox split off the front axle. Scored well with the gearbox, it is tip-top shape. Just the gearbox axle seals need to be replaced, this will involve taking the wheels, hubs, axle boxes, and bearings off. I sincerely hope I have better luck with setting this axle up than the Wickham's, that was a nightmare.
From here, there is a lot of parts need stripping, cleaning and repair. From my other restorations it has taught me this is a slow process but certainly worth it when a shiny trike rolls out of the shed.
Now, what's up with Wickham 526 you ask? No? Well I'm going to tell you anyway.
526s primary engine turned into an oil pump. The bore I used was worn 0.008 of an inch oversize. This was an oversight on my part, I assumed the bore was good as there were no signs of wear and no lip in the cylinder. At the time I had no way to measure this wear. Anyway long story short, the engine was a smoke machine and emptied the sump in a little over 2hrs of running.
I got hold of a brand new 0.020" oversize piston and ring set, bundled them up with the cylinder bore and they are in the process of being matched.
Currently 526 is fitted with it's back up engine.
The engine was removed first and given a blown down test. This test involved a modified spark plug to hook up compressed air to the engine. By listening in the exhaust and inlet ports for air escaping it told you if the valves were leaking or not. If air was escaping through the crankcase filler, you would know the rings were worn. Cylinders 1 and 2 inlet valves and 3 and 4 exhaust valves leaked. The heads were removed and taken to a machine shop to have the valves re done. Wickham 526 cylinder bore is also in the shop for re boring (more on that later). The clutch and the flywheel was removed, low and behold the clutch is brand new, someone put it in and never used it, still got the paint markings on it. A new flywheel seal was installed and the clutch re-assembled.
The tin ware is awaiting stripping and cleaning then to be painted and waiting on new head studs and exhaust before the engine will be re-assembled. Engine parts are plentiful for the old donk, lots of aftermarket gear available but try getting a muffler for one. The rear axle of the car is so close to the exhaust it must have a stock one fitted. A search of over 30 vendors resulting in just one being able to supply the muffler and that one still had to order it in for me.
My Father has been doing the mechanics on the VW engine, it's one of his specialities.
Many things are rusted beyond repair and had to cut off, lots of stuff will have to be rebuilt or remade. Just today the axles were taken off and the gearbox split off the front axle. Scored well with the gearbox, it is tip-top shape. Just the gearbox axle seals need to be replaced, this will involve taking the wheels, hubs, axle boxes, and bearings off. I sincerely hope I have better luck with setting this axle up than the Wickham's, that was a nightmare.
From here, there is a lot of parts need stripping, cleaning and repair. From my other restorations it has taught me this is a slow process but certainly worth it when a shiny trike rolls out of the shed.
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| The tin ware. |
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| The motor with the heads on |
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| without heads |
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| Clutch and flywheel |
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| Rotten timber panels |
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| Caren shaft, front and rear axles |
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| Crown gears on the from axle. I'll have to get a comparison photo to the Wickham's gears. |
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| The gearbox. |
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| Clutch housing |
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| The bare chassis |
526s primary engine turned into an oil pump. The bore I used was worn 0.008 of an inch oversize. This was an oversight on my part, I assumed the bore was good as there were no signs of wear and no lip in the cylinder. At the time I had no way to measure this wear. Anyway long story short, the engine was a smoke machine and emptied the sump in a little over 2hrs of running.
I got hold of a brand new 0.020" oversize piston and ring set, bundled them up with the cylinder bore and they are in the process of being matched.
Currently 526 is fitted with it's back up engine.
Saturday, September 22, 2012
Friday, September 21, 2012
The butt kicking continued...
...thankfully not for much longer.
Last Friday evening 526 was loaded ready for an early departure to Crookwell on Saturday morning. Having not towed a trike for some time I had forgotten how heavy they drag from weight and wind. None the less, Dad and I arrived safely and on time.
We unloaded 526 onto Crookwell goods siding. The area has the earth level with the head of the rail to load and unload trikes. Started the trike, we all got on, moved half an inch...SNAP! there goes the throttle cable. For 3 weeks I have been wrestling with 526's problems, it seemed it didn't want be repaired. It didn't help either when we found out that the key for the 'C' frame has been lost and we couldn't get 526 out of the siding. A trip to a hardware shop to get yet another soldering iron, solder and some cleaning fluid to solder the end back on the cable.
Despite the hassles, hold ups and money poured into 526 recently, once it was back on the rails for the next 2 and half days it ran perfectly. The induction weekend was a success with 526 passing it's inspection and issued a certificate of accreditation to operate within the GCHR.
I also got to catch up with a friend, Allan Robinson. He was the one that organised 526 to be sold to my uncle back in 1988. I learnt that 526 was used on the Mudgee branch and stationed at Kandos. Wickhams on that branch were in numerical order. Kandos had 526, Rylstone had 527, Lue had 528 and Mudgee had 529. I have 529's way and works plate.
526 requires a couple more tweaks. A new throttle cable to be fitted and replace the ignition coil resistor. Other than that it's ready for anything...I hope ;)
Last Friday evening 526 was loaded ready for an early departure to Crookwell on Saturday morning. Having not towed a trike for some time I had forgotten how heavy they drag from weight and wind. None the less, Dad and I arrived safely and on time.
We unloaded 526 onto Crookwell goods siding. The area has the earth level with the head of the rail to load and unload trikes. Started the trike, we all got on, moved half an inch...SNAP! there goes the throttle cable. For 3 weeks I have been wrestling with 526's problems, it seemed it didn't want be repaired. It didn't help either when we found out that the key for the 'C' frame has been lost and we couldn't get 526 out of the siding. A trip to a hardware shop to get yet another soldering iron, solder and some cleaning fluid to solder the end back on the cable.
Despite the hassles, hold ups and money poured into 526 recently, once it was back on the rails for the next 2 and half days it ran perfectly. The induction weekend was a success with 526 passing it's inspection and issued a certificate of accreditation to operate within the GCHR.
I also got to catch up with a friend, Allan Robinson. He was the one that organised 526 to be sold to my uncle back in 1988. I learnt that 526 was used on the Mudgee branch and stationed at Kandos. Wickhams on that branch were in numerical order. Kandos had 526, Rylstone had 527, Lue had 528 and Mudgee had 529. I have 529's way and works plate.
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| 526 at the Crookwell Railway Station |
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| The 'Works' convoy ready to head out for track repairs on Sunday 16th |
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| Wickham twins 526 and 617 together again. 617 was mine, I sold it in 2010 |
526 requires a couple more tweaks. A new throttle cable to be fitted and replace the ignition coil resistor. Other than that it's ready for anything...I hope ;)
Thursday, September 13, 2012
The high's and low's
It's done, finally Wickham 526 is in one piece and running. The rebuilt engine works a treat, the new exhaust is quiet, the clutch operates as it should, the new wheel bearing are aligned and smooth.
It's all good except for that front axle... It's bent...(insert Lucile Ball Whaaaaaaa here).
Even this has an upside though, I've become very proficient in removing and replacing the axle. The hardest part is up-ending the trike so the skid rails can be removed.
The bend is very slight and was not picked up until the trike was jacked up so the wheels could spin while the gearbox was tested. A number of solution are being weighed up, fixing the original axle, having this axle straightened or source another axle. The latter is a long shot given that type 4 Wickhams and parts seem to be very rare in the market place.
Speaking of the market place, an SIC went off on eBay recently. I was surprised at what it went for given it's condition. However it a promising sign that there is still interest in the hobby.
Anyway, I'm looking forward to this weekend in Crookwell, 526 is going to get real workout.
It's all good except for that front axle... It's bent...(insert Lucile Ball Whaaaaaaa here).
Even this has an upside though, I've become very proficient in removing and replacing the axle. The hardest part is up-ending the trike so the skid rails can be removed.
The bend is very slight and was not picked up until the trike was jacked up so the wheels could spin while the gearbox was tested. A number of solution are being weighed up, fixing the original axle, having this axle straightened or source another axle. The latter is a long shot given that type 4 Wickhams and parts seem to be very rare in the market place.
Speaking of the market place, an SIC went off on eBay recently. I was surprised at what it went for given it's condition. However it a promising sign that there is still interest in the hobby.
Anyway, I'm looking forward to this weekend in Crookwell, 526 is going to get real workout.
Tuesday, September 11, 2012
Yep, they are different
Not all Wickham rail cars are created equal.
The gear box is back in pieces and now the front axle has to come back out and have all the shiny new paint damaged. The axle bearings need to be removed to replace a crown wheel for the forward gear.
Over the vehicles life in the type 4 Wickhams had design changes with the gearbox, only slight ones, but enough to to make parts incompatible. In my case the pinion gear does not mesh with one of the crown wheels in the gearbox. The crown wheels gears are a tad deeper than the other one. This caused the axle to bind when the gearbox was tightened up on the axle.
I'm now back to where I was 2 weeks ago. Yippee!
The gear box is back in pieces and now the front axle has to come back out and have all the shiny new paint damaged. The axle bearings need to be removed to replace a crown wheel for the forward gear.
Over the vehicles life in the type 4 Wickhams had design changes with the gearbox, only slight ones, but enough to to make parts incompatible. In my case the pinion gear does not mesh with one of the crown wheels in the gearbox. The crown wheels gears are a tad deeper than the other one. This caused the axle to bind when the gearbox was tightened up on the axle.
I'm now back to where I was 2 weeks ago. Yippee!
Saturday, September 8, 2012
Solid progress at last
To catch up on progress of the repairs to Wickham 526 see my other blog Lines near the Lachlan
The worn axle problem was solved...got another axle. The 545 project is on indefinite hold (545 is another type 4 Wickham) and so has provided many parts to 526. The rear axle was worn as well but it was solved by pinning the axle and using Loctite 603 retaining compound. The axle boxes also needed Loctite to hold the outer bearing race.
The front axle is now assembled and test fitted. The rear one just needs packing with grease and test fitting before both are ready for painting.`
The worn axle problem was solved...got another axle. The 545 project is on indefinite hold (545 is another type 4 Wickham) and so has provided many parts to 526. The rear axle was worn as well but it was solved by pinning the axle and using Loctite 603 retaining compound. The axle boxes also needed Loctite to hold the outer bearing race.
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The replacement axle having the crown gears, gearbox bearing and seal fitted
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The front axle boxes cleaned up and associated parts.
The metal rings in the foreground are the bearing spacers that I had made up.
The front axle is now assembled and test fitted. The rear one just needs packing with grease and test fitting before both are ready for painting.`
The test fitting of the front axle
All while this is going on, it was noticed that some gears in the gearbox were missing a couple of teeth, a result of metal fatigue. Once again the other wickham came to the rescue providing serviceable gears that look to have done very little work. I also took the opportunity to replace the bearings.
A little chip in the smaller gear
This is the driven gear for low speed.
The local muffler shop bent up a new exhaust system. It wasn't a necessity to replace the original but it something that won't have to worry about later on.
New muffler with the tail pipe already welding in.
What dad calls the 'trombone'. The exhaust pipe that runs from the engine to the muffler that is located under the right running board
It is important to finish 526 in six days ready for running trials in Crookwell to see if all the work has made improvements. The 15th and 16th September is an induction day at the Goulburn Crookwell Heritage Railway for trike operators. Member will have their trikes check over and tested for operator competency.
Dad and I attended the first induction meeting of the Motor Car Consortium Limited (MCCL) on the 1st and 2nd September. It was great to meet several members and put faces to the names. The Lithgow State Mine Heritage Park and Railway hosted the group for the weekend with the meeting held in the Eskbank Railway Station and later were given a tour of the State Mine complex including the commercial operations. The MCCL is is well advanced in to gaining accreditation to operate in NSW. For more information contact the consortium through their website.
MCCL CEO Nic Doncaster runs through what is required for motor car accreditation.
Tuesday, September 4, 2012
New Blog
Hi Everyone
NSWGR Trikes joins the blogging community. This is to separate my interests of HO model railway and New South Wales perway vehicles, commonly called trikes, section cars, trolleys, rail motor cars.
Lines near the Lachlan has already some entries about my trikes. Have a squiz to catch up on what I'm up to.
NSWGR Trikes joins the blogging community. This is to separate my interests of HO model railway and New South Wales perway vehicles, commonly called trikes, section cars, trolleys, rail motor cars.
Lines near the Lachlan has already some entries about my trikes. Have a squiz to catch up on what I'm up to.
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