Lister Engine Forum
Slow Speed Diesel Engines => Other Slow Speed Diesels => Topic started by: listerdiesel on September 25, 2009, 10:29:31 PM
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Various happenings while the forum has been down, and also I haven't had a lot of spare time to chat or show what's been going on, but here are the pictures of the Ruston & Hornsby 1ZHR diesel and the new trolley and chassis. There is a Start-O-Matic alternator that is going onto the end of the chassis, that was reconditioned earlier in the year. The pulleys and layshaft are for the speed step-up to get 1500rpm out of the Ruston's 375 rpm.
First picture is the trolley (Ex Trident aircraft aircon rig) with the chassis frame mounted loosely on top.
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley7.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley8.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley9.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley10.jpg)
Then we have the bolted down frame.
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley11.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley12.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley13.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley14.jpg)
The engine is put on bit by bit (It all has to come off again....)
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley15.jpg)
Holes drilled for the 3/4" or 20mm through-bolts to hold the engine down (3 bolts only)
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley16.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley17.jpg)
Couple of closer shots of the engine with the crankshaft laid in place.
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley18.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley19.jpg)
Couple of shots of the layshaft and the flywheels in place (34" diameter)
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley20.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley21.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/BombTrolley22.jpg)
It's only a display unit, it will not be used for house power as we don't get that many power cuts in the UK, and we have any number of Onan and Villiers-powered gennies around the place to run electrics for a few hours.
Peter
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Looks very nice Peter keep us posted
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Will do, the Start-O-Matic alternator rebuild was done earlier this year, I might put those pictures up if there's enough interest.
The pictures all were taken with a Sony Mavica 1.2mp camera, not bad! It is almost as good as my Sony 5mp for sharpness.
Peter
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The Start-O-Matic alternator was bought secondhand for £65 including the remains of the top control box.
We stripped the alternator down and went through the unit, changed the main bearings but most of what was left was pretty goo.
The pictures tell most of the story.
At the start, the armature was taken out, cleaned up and skimmed. Bearings changed etc.
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM2.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM3.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM4.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM5.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM6.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM7.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM8.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM9.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM10.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM11.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM12.jpg)
The stator needed a bit of TLC, and the leads were cut and extended with new cable, and the smaller ones sleeved in some high-temperature woven material sleeving. Brushes and holders were cleaned up and checked
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM13.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM14.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM15.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM16.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM17.jpg)
Most of the following are shots of the brushgear and the lead-out repair.
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM18.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM19.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM20.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM21.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM22.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM23.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM24.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM25.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM26.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM27.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM28.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM29.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM30.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/SOM31.jpg)
I'll post some more as soon as I get a minute or three ;)
Peter
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Peter I have a little discomfort looking at the general conditon of that Alternator and being returned to service in that condition.
In your place I migh look to buy a gallon of light Naphtha and a soft brust and try and clean any grease and oils off before I went any further. I know you have some experience with this sort of thing with this sort of thing from the railway and its obvious from the way you have made ther repairs but I think a good solvent cleaning and a coat of air dry varnish would go a long way to protecting your investment in time and effort.
Doug
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Hi Doug:
Sorry I couldn't reply earlier, we are a bit busy with 'end of the month' builds to get out!
The armature and field coils were flash tested OK, and the general condition is better than it may appear in the pictures.
It won't be running 24/7, so i don't see a problem, but you'll be the first to hear if we do! ;)
Peter
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No problem I understand. Lucky you for being buisy, I haven't worked since June....
My feeling is because of the age and the Organic materials used in the insulation it may need a little help.
You say you gave it a poke with an insualtion tester and it looks OK, that great! However once warmed up in service that value will drop. Its juts the nature of old windings.
The cost of a quick clean and spray with some Air dry is very little. Replacement however is considerably more.
Again its just a feeling but that insualtion looks to me to have suffered some oil and grease contamination and this combined with the natural degrading of organic material with age and exposure to oil and Carbion brush dust bother me some.
There' s nothing I can do from here it you run into some trouble with it but in your possition an ounce of preventions is worth a lorry of !@#$%# lol.
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I also vote for my disturbed state about this windings condition of stator and rotor.
Get the gunk out with degreasers and have motor shop check it out and baked to dry out, if test passes the insulation test, dip both for insulation renew and mechanical integrity JUST in case!
Cheers, Wizard
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Fast-forward a month or so, the beast is almost ready, we have had it running, there are some videos on YouTube under my username.
Here's an assortment of the latest pictures:
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics67.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics68.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics72.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics82.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics83.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics84.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics99.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics100.jpg)
Still plenty to do, and we sail for Holland on the 21st May!
Peter
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It's all running now, there are some videos on YouTube under my username, here are the three latest ones showing the electric starting, the last one is where we have it up on wooden blocks as it was bouncing a lot on the trolley tyres:
First one is a shot as the engine is started on the motor.
http://www.youtube.com/watch?v=kIw0v7HE494
Next is Rita starting it up while I shoot the sequence.
http://www.youtube.com/watch?v=5vlWk3YNZhY
Last is the engine running while up on the blocks.
http://www.youtube.com/watch?v=PUEAamOI-2A
Peter
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Thats a beauty !! Some very nice detail work there Peter !!
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That is absolutely beautiful.
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Just a bit of an update:
We took the engine to the Nuenen Stationary Engine show on the Dutch Whitsun weekend, we hadn't sorted all the electrics out, but it ran for three days off and on, the drive side was fine, the engine we ran up to 80 dec C then shut if off to cool down, the water tank was losing water through splashing out of the top and uncovered the top feeder pipe which stopped the circulation.
Going to re-jig the rotation of the Start-O-Matic unit to bring it back to normal rotation. It is at present running backwards to suit the 1ZHR's rotation.
We did forget to load the starting handle, so the Start-O-Matic starting function really had a good test.
Picture below of us as we left the rally field yesterday morning (Tuesday) to drive to the Ferry.
(http://www.stationary-engine.net/Forum/Images/Uploaded/Nuenen221.jpg)
Peter
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Must have some special gear in you car, looks like you are towing more than the car weighs !! Wonderful restore job. :)
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Thanks, Mike:
The trailer and engine/trolley weighed in at just on 2.5 tons, the Disco is 2.2 tons empty, so with 3 adults and all our camping gear we were probably up to 2.5 tons there as well.
It's a V8 4litre engine, 183hp but we run it on LPG to keep the costs down.
Peter
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Since my last post, we have reversed the mounting of the alternator, re-instated the starter field the 'right' way round, and got the belts and drive all on the same side.
That left us room for the control cabinet which will house the four 6" meters which show battery volts and charge current, output volts and output current. The as yet unpainted 2" X 2" X 1/4" ali angle in the pictures are the mountings for the cabinet's rubber isolators. Two of the re-scaled meters shown below, the original scales were scanned, then digitally modified and then printed on photo-paper and stuck onto the back of the original scales:
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics148.jpg)
We picked up a duplicate set of the very nice Crompton Parkinson meters last week, completely by chance.
Earlier this week we sorted out the rev-counter stand, and today we finally got volts and amps out of the beastie!
Once we were able to flash the generator field with Philip's little variable power supply, we started to see some activity on the voltage side.
At more or less nominal rev's, we were getting 33V, and it appeared that the field resistor was back to front, with too much resistance in the circuit between the brushes and the field.
Once that was changed round, we had 235V on the output, and a load was quickly organised to try the output compensation field.
We had a 1.5kW radiant heater which was a decent starting load, and we dropped 5V when that went on line. Given that we are probably not trimmed up for optimum output, that's fine, and after a few minutes running it has slightly risen in volts.
Battery charging is going to be fine also, there is 36V DC available from the dynamo side of things, and we will have to make up a small regulator circuit that will allow charging of the sealed batteries while limiting their maximum voltage.
Lister used a couple of resistors with a link, so that a high or low charge rate should be selected. That was fine for wet batteries, but not suitable for modern sealed batteries.
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics181.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics182.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics183.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics184.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics185.jpg)
That leaves the way open to get the cabinet finished off, and the metering and output circutry wired up.
Peter
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More work has been done, I haven't posted all the build/modification stuff, but we had the control cabinet up and wired in, then gave it a run to see how it all worked on load.
The Start-O-Matic alternator ran well, barely warm on a very hot day at 1.5kW load (resistive) no problems with any of the drive belts etc., and we have the luxury of a battery charge as well!
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics212.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics213.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics215.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics217.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics219.jpg)
Peter
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Beautiful setup! I like the electrical gauges -- are they new or vintage? (EDIT -- duh! Just read the earlier posts....)
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What a beauty Peter, and people are telling me not to get a CS because they are too big ;D Thats a beast of a Discovery you have their as well......... :o
Chris
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Beautiful setup! I like the electrical gauges -- are they new or vintage? (EDIT -- duh! Just read the earlier posts....)
Strange to relate, we picked up an identical set from an ebay vendor, he advertised one which I recognised, and then it turned out that he had the whole set, for for less than $80 I had a duplicate set of meters. Then, he says that he has a THIRD set but later types and square, so he threw them in with the others!
I'm just anchoring the engine, or rather providing a couple of adjustable restraints, as it is creeping along the bed of the main frame under the tension of the drive belt which is driving something on the trolley frame.
We have also added an extra tap to the charge resistance and a 2-way switch, so we have about 1-1/2 amps and 3-1/4 amps charge rates, similar to what Lister did on the Start-O-Matics.
Peter
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What a beauty Peter, and people are telling me not to get a CS because they are too big ;D Thats a beast of a Discovery you have their as well......... :o
Chris
The 1HR's are the smallest in the range, the 1ZHR is the biggest of the 1HR series. 2HR and above are getting too big to move easily, but I wouldn't turn one down if it came along. 8)
Peter
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Peter,
What a great project executed with fine workmanship, engineering, and attention to detail. Congratulations!
Bob
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We had a longish run under load today, to see how the temperature rose while on load and on a fairly warm day. Top temperature was 94 Dec C or just over 201 deg F in old money.
We only had 1.5kW loading, as the main objective was to give the engine something to work against, rather than just run it offload and have bore glazing issues.
We also trimmed up the output voltage, we now have 235V.
A bit of maintenance on the oil drain passages produced a lot of rubbish that was blocking the main drain tube, and we also ran a spanner over the ring oiler while the crank guard was off.
The alternator gets mildly warm, only about body temperature, if that. The cooling fan is audible, bit of a drone, but otherwise it has sealed bearings and is virtually maintenance free.
Youtube video here:
http://www.youtube.com/watch?v=vsNfziTsKRc
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics227.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics228.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonPics229.jpg)
Peter
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That's a lovely bit of kit you've made there Peter, the only thing missing now is some sort of kettle attachment to brew up a nice cup of tea with all that hot water you've got stored!
perhaps you you can find some screw down feet for it something beefy with Acme square threads that you can steady the whole works and get it off the wheels a bit.
Regards
Robert
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It is already sitting on 3pces of 8" X 3" timber on each corner, it bounces too much on the tyres (tires) ! ::)
We will probably leave it 'as is' for the rest of this year and see what other balancing options we have.
The coolant has OAT additive in it, probably make the tea taste funny! ;D
Peter
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Apologies, I thought that the video editing had produced a single long video, in fact it had separated each chapter into a separate MPEG file, and I had only uploaded the first one to YouTube.
First section:
http://www.youtube.com/watch?v=vsNfziTsKRc
Here are the rest of the sequence:
http://www.youtube.com/watch?v=EXEYG-k6kBc
http://www.youtube.com/watch?v=mfuDmkPfsRs
http://www.youtube.com/watch?v=aMOKlVANA2Q
http://www.youtube.com/watch?v=ilzLwhxvFJQ
http://www.youtube.com/watch?v=kzgYfCTFUhw
http://www.youtube.com/watch?v=AZ_vqvYoph4
http://www.youtube.com/watch?v=rVzRQIQBDqI
Peter
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Took the Ruston out to a show over last weekend, here are a couple of pictures.
We did have an internal wire which lost its insulation while getting too close to one of the through-bolts in the alternator, but it's all OK now.
(http://www.stationary-engine.net/Forum/Images/Uploaded/Barleylands1.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/Barleylands2.jpg)
Peter
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Thanks for sharing your wonderful Ruston project which i have been following the last couple of months. Your passion in setting up this beauty is truly beyond my words.
My 78 years old dad would nod his head with admiration whenever he see those pics of your Ruston. He being an engine driver for many Ruston Genset during his younger days.
warmest regard, swlee aka startomatic from Malaysia or Malaya during the heydays of Lister and Ruston Diesel.
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We have converted the rebuild thread on the UK Forum into webpages on our websites, just the rebuild posts and pictures, up to June/July this year. There are over 200 pictures, most of which have not been shown here on listerengine.com.
The links are here:
http://www.stationary-engine.co.uk/Ruston1ZHR/Ruston14.htm
http://www.oldengine.org/members/diesel/Ruston1ZHR/Ruston14.htm
It starts in February 2009, the engine was craned out of its hiding place at the back of the house in December 2008.
Peter
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Since our last post we have been designing and building a new trailer, one that will combine the hauling of the Ruston plus living quarters for us while we are away from home, known as a 'Toy Hauler' in the USA I believe.
The design work started last summer, and the actual chassis work was finished in early March. We are waiting for the chassis frame to come back from being shot blasted and Zinc sprayed, then it goes for powder coating.
All of the extrusion sections for the body are here, we just need to order the GRP/Plywood sandwich panels for the sides when we are ready for them.
Pictures below of the finished chassis before we left the fabricators. We spent two and a half days with them, our youngest did a fair bit of the welding with our own industrial MIG set.
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBTrailer132.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBTrailer133.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBTrailer134.jpg)
Extrusion pile:
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBTrailer139.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBTrailer140.jpg)
Peter
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such tiny tires for a heavy load ??
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Hi Mike:
The trailer all-up weight is 3500kg, the max tyre load is 4380kg, 730kg each, so we have a bit in hand.
Tyres are 175R13C, load rating 97, Hankook RA08 light van.
The bare chassis as in the pictures weighs dead on 800kg.
Peter
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Things have moved along quite nicely:
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis59.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis72.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis73.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis74.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis75.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis76.jpg)
Peter
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Update from Monday:
Lots of things happening today, I arranged for another brake cable to be here for the morning, that should enable things to be finalised on the brakes.
(The issue was the anchor point of the cables. If behind the pivot point on the drawbar, ie on the swivelling part of the axle, the tension on the cable will vary with the bending of the joint in the drawbar, that was what was niggling me the other night)
The windows turned up, so they went in pretty quickly, no big problems and they are nice quality. Fairly heavy, but so was the whopping great lumps of GRP/Ply that we jigsawed out.
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis151.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis152.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis153.jpg)
Makes the interior much more comfortable and every window is ventilated with a top 'hopper' vent, so I haven't got to rush to fit the roof vents now
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis154.jpg)
Also you'll note the white box alongside the loo/shower window, that is the external power inlet box and socket.
All wired in but can't find an extension lead here for the mains! :embarrassed:
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis155.jpg)
Peter
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Update from 06/06/2011:
A few pictures that I took this morning after it stopped raining:
Drawbar Parking
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis147.jpg)
Internal Electrics
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis148.jpg)
Winch & Batteries
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis149.jpg)
Finished Bulkhead
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis150.jpg)
There is an external power inlet to go onto the trailing blue cable, we just hooked it up to give the batteries a charge.
Peter
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I just have to ask.
You guys that do this perfect work also usually get a lot of it done. Did I just stay home and watch too much daytime TV as a kid or was your finger painting also post-impressionist with subtle overtones of cubism?
Too bad NASA didn't get you to do the shuttles. They'd still be ready for another 25 years service.
Bravo Mr. listerdiesel.
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That is a thing of beauty! Looks like a million bucks!
dieselgman
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Here are a few images of the beast parked outside the factory the day before we left for Holland and the Nuenen engine show:
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBTrailerFinished1.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBTrailerFinished2.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBTrailerFinished3.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBTrailerFinished4.jpg)
Here is one of the rather nice and rare engines at the show, a Thomassen gas engine:
(http://www.stationary-engine.net/forum/attachment.php?attachmentid=7290&d=1308062151)
Have been to Holland and back, no trailer issues at all, and the Ruston 1ZHR ran for two full days without a stop.
Peter
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I just have to ask.
You guys that do this perfect work also usually get a lot of it done. Did I just stay home and watch too much daytime TV as a kid or was your finger painting also post-impressionist with subtle overtones of cubism?
Too bad NASA didn't get you to do the shuttles. They'd still be ready for another 25 years service.
Bravo Mr. listerdiesel.
Concepts are great, and can take a lot of time, but if you think that is bad, actually producing something like this is a whole lot worse!
There are about 30 separate drawings for the various bits and pieces, and some of those run to 6 or 7 issues. It didn't happen quickly and there were many compromises along the way. The cooker, shower, toilet and fridge still remain to be fitted, plus the Autogas refillable LPG tank and piping. We are very pleased that it has turned out OK and that it tows very well, better than expected.
We also need to take some weight out of the trolley that the Ruston sits on, we have to trim 1/4 ton somewhere.
Peter
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What a great job Peter, engine and trailer !!
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Stunning Peter!
I would like to order a 40' version. Would you mind tossing in a big screen TV and hot tub? Also, would you be available to deliver it here in the US?
In all seriousness, beautiful work!!!!
Are the sides one continuous piece of the foam material or does it come in smaller sheets (it's hard to see seams if they are there in the pics)? Also, what is the roof made of? Again, one continuous piece?
Lastly, I love the folding hitch idea as it cuts down on the overall length nicely!
Just a fantastic job! Can't wait to see the finished pics of the inside as well.
WOW!
Best regards,
Steve ;-)
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Steve:
The sides are sheets of 14mm GRP/Ply/GRP sandwich, the honeycomb was used for the flooring and the bulkhead between the living quarters and the engine.
The side sheets come as one piece, and even after we had cut them down to size and cut out the wheel arches etc., it still took 4 of us to pick them up and put them in place.
The roof comes on a continuous roll of 1.3mm GRP. It is riveted to the cant rails all round at 220mm centres, and stuck to the roof bars with double-sided tape.
Peter
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Bit more work done over the past week or so, we made up the false wall that the cassette toilet sits on and got that fitted into place, 120mm forward of the actual wall/divider.
We have a huge amount of GRP/ply and honeycomb left over, so it's just a case of picking a piece that's near enough in size and trimming it up. Two bits of 3/4" angle were used to fasten it to the outside wall on one side and the new kitchen side wall the other.
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBTrailerInt5.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBTrailerInt6.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBTrailerInt7.jpg)
There is a 'hook plate' that the toilet sits onto, and there are three screws farther down which are going to be fun to get in. The whole assembly sits on a styrofoam padded base, and we have raised it up by 15mm so the outside cassette access door will clear the side rave extrusion.
There is a path under the shower tray edge, under the toilet left-hand side and through both walls for the hot and cold water hoses and anything else we want to run from front to back.
Pictures are a bit wishy-washy, didn't take them until after dark.
We have the covering extrusion for that big join in the divider, and are planning to fit that tomorrow evening. The screw heads will be this side of the wall!
Peter
Edit:
Got the extrusion fitted over the bulkhead gap, and reversed the screws so that the smooth heads are the bathroom side.
The H and corner extrusions arrived today, not particularly cheap but exactly what we need. The supplier has a minimum order charge so we just added more extrusion to make up the price.
Cut that tonight and had a trial fit of the panels, looks OK but we have a 1mm panel width difference between the channel and the panel, so will need to address that.
Went through the cassette toilet templates again, had to do a bit of patching up of old tears etc, but we have now made some sense out of it all and expect to cut the aperture on the weekend.
Edit 2:
Spoke to Thetford again about the new templates for the toilet, they say they will be here on the 27th. The set we have don't match the outer door, and I'm leery about cutting a big hole in the side without knowing it's going to be OK!
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Are the sides one continuous piece of the foam material or does it come in smaller sheets (it's hard to see seams if they are there in the pics)?
Best regards,
Steve ;-)
Here are a couple of the pictures of the sides as we were cutting them down:
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis31.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/DBChassis32.jpg)
The second shot is the 8ft X 8ft panel for the front.
Peter
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Part of the current work is to lose about 600 lbs weight from the engine, as the trailer is slightly overweight.
The 6-wheel trolley that is under it now has to go, and we are making up new axles with wheels from a 1940 Bren gun carrier (Universal carrier) made by Ford Motor Company of Canada.
Here's a few pictures of what we have been making up recently:
Carrier wheels after being fired to remove rust and the remnants of the moulded-on tyres (molded-on tires)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolley1.jpg)
Axle beams and stub axles:
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolley2.jpg)
Stubs about to be welded into the tubes, each one is 2" diameter steel, with an 1-7/16" hole drilled up the centre to save weight:
(http://www.stationary-engine.net/Forum/Images/Uploaded/TrolleyAxle2.jpg)
Axles almost finished, turntable disc and pivot bolt to go on one of them:
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolley13.jpg)
Disc welded on, just waiting for the M30 bolt:
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolley14.jpg)
Painting the wheels after shot blasting and Zinc spraying:
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolley15.jpg)
Glueing the tyre strips on:
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolley16.jpg)
Tyres all stuck down, just need trimming and wheel bearings fitting:
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolley19.jpg)
Tonight's efforts, chamfering the tyres and fitting the wheel bearings:
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolley21.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolley22.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolley23.jpg)
Peter
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Got the axle stubs cleaned up and the wheels slid on:
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolley29.jpg)
Started making the bearing covers last night.
Peter
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Busy day at the factory, got the Ruston off the 6-wheeled trolley and on to the new axles and wheels:
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolleyebay1.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolleyebay2.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolleyebay3.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded/RustonTrolleyebay4.jpg)
The trolley is on ebay, got a bid within minutes of it being listed!
Peter
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.....
The trolley is on ebay, got a bid within minutes of it being listed!
Something that good looking and you are selling it ?? Dang !
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Something that good looking and you are selling it ?? Dang !
Gotta go, haven't the space to keep it, and better it goes to another good home than sitting around rusting away.
Peter
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Trolley went for more than double what we paid, so pretty happy with that!
Went to the Barleylands show at the weekend, the Ruston ran 2 days continuously, just the occasional short stop for oil and fuel, running a lighting load of 1kW to 2kW.
(http://www.stationary-engine.net/Forum/Images/Uploaded2/Barleylands18.jpg)
Peter
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Been watching this thread all along Peter and I must say WOW! that sure is one fine looking outfit!
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Been watching this thread all along Peter and I must say WOW! that sure is one fine looking outfit!
Thanks for the nice comment, it has taken a while to get here, but it is almost where we want it to be, just a few odds and ends to do over the winter. That includes a proper stand for the control panel cabinet and some better lashing eyes for holding it down in the trailer.
The weight-saving with the new undercarriage was 306kgs or 673lbs or 6cwt.
Total engine and trolley/generator weight is 1386kg or 3049lbs or 27.225cwt. (1cwt or hundredweight = 112lbs) that includes the six timber blocks that we carry with it for putting under the wheels when on soft ground.
Peter
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Interesting, it looks a lot lighter than its 1 & 1/3 tons - is that dry weight? And I must admit, I wouldn't want to try to pull that out of a muddy field after a typical British weekend...
Incidentally, in America, the engine would weigh 1.5 (short) tons, or 30.5 short cwt... which I guess is why they work almost exclusively in lbs, as that's the same weight here in Blighty.
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Interesting, it looks a lot lighter than its 1 & 1/3 tons - is that dry weight? And I must admit, I wouldn't want to try to pull that out of a muddy field after a typical British weekend...
Incidentally, in America, the engine would weigh 1.5 (short) tons, or 30.5 short cwt... which I guess is why they work almost exclusively in lbs, as that's the same weight here in Blighty.
I am confused ???
If I were to purchase it would it be heavier, or lighter when it arrives stateside,, than when when it left England? ;D ;D
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Well, America is a bigger landmass than the UK, so I'd expect its gravitational pull to be slightly higher, i.e. the engine would be heavier. Unless there were a full moon of course, in which case it would be lighter.
In a worst-case scenario, if Jupiter and Saturn align with Uranus, and they all ganged up with the moon & the sun, then the old Ruston might just float away in the breeze. Which is why you must always cover Uranus in these situations.
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when you were talking lbs I thought for a second you were talking foreign currency exchange devaluation. ;)
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Interesting, it looks a lot lighter than its 1 & 1/3 tons - is that dry weight? And I must admit, I wouldn't want to try to pull that out of a muddy field after a typical British weekend...
The handle/drawbar has a 50mm standard trailer coupling bolted on to it......
Weight was without coolant but there was oil in the crankshaft reservoirs.
Peter
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We've been thinking about a video slideshow to go with the engine at shows, so that folks can watch a reasonably detailed timeline of the work that we did on the engine, and have put together a prototype:
http://www.youtube.com/watch?v=NyBz1XyM1Dk
Still a bit rough round the edges in places, but it has the bones of what we want to show. As we have 230V AC available, we can run a standard small format PC and LED/TFT screen to show it.
There is no sound.
Peter
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Up to Version 8 now, probably as far as we will go with it. Larger pictures of the earlier stages and a bit more descriptive text.
http://www.youtube.com/watch?v=2yR3Ch2KWtY
Peter
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Thanks! I like your video, it gives me ideas. Maybe we can do something similar for instructional purposes with the other Lister engines. We do have an old 1960s Lister professionally produced 8mm movie doing the same for servicing the S series but that is the only AV piece I have ever seen for the Lister and it is sometimes less than clear for the average non-tech person. What computer applications were used in your production?
dieselgman
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The Slideshow software is Photostage, by an Australian company called NCH Software.
http://www.nchsoftware.com/slideshow/index.html
There is a free version, we bought it as we do with all our software that we use a lot.
Works fine, converts to various formats at the end.
The other software that we use is by AVS, AVS Video Editor, AVS Video Converter.
Basic picture editing we use Paint Shop Pro, V7 and V8.
Peter
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Spent a bit of time on Saturday, getting a couple of the jobs done, the main one was the new lashing eyes:
(http://www.stationary-engine.net/Forum/Images/Uploaded2/RustonTrolley72.jpg)
We also fitted an extra eye for the trailer winch:
(http://www.stationary-engine.net/Forum/Images/Uploaded2/RustonTrolley73.jpg)
The eyes are M12 size in Stainless Steel, because of their proximity to the trailer hooks, we are using only the doubled-up portion of the ratchet strap, which gives a useful extra bit of strength.
The eyes in the first picture are bolted through the water tank frame and the engine frame, and in the second picture they are bolted through the engine frame with some extra reinforcement inside the box section.
Peter
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As the end of the rally season has gone, we have winterised the Ruston for the long sleep.
The last outing was to the Anson Engine Museum, they hold an 'End of Season' weekend and we were up there with the engine on the Sunday.
As the engine spends all its life outside, the main things we do to protect it are greasing the crankshaft ends and fitting heavy plastic bags over them, held on with cable ties. The water is always drained after each show so there's none in there, the bare metal parts are greased or sprayed with WD-40 and the engine is turned onto the compression stroke so both valves are closed.
We have two heavy pvc/nylon truck sheets that we cover it with, keeps all water out but allows a bit of air underneath to combat any condensation. It's been stored like this since we have owned it and it keeps it in fair order.
The batteries are charged at Xmas time, although they rarely need much, and we give the engine a check over and run in the New Year, just to blow any cobwebs out. The fuel is left in, it normally has half a tank remaining and it will keep until the next trip.
First outing in 2012 will probably be to Nuenen in May.
Peter
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The fuel is left in, it normally has half a tank remaining and it will keep until the next trip.
Would it not better to fill the tank so as to reduce the airspace in it and consequent condensation?
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Would it not better to fill the tank so as to reduce the airspace in it and consequent condensation?
It isn't an issue normally, there aren't big temperature swings where it is, and we have two PVC/Nylon heavy truck sheets over it to keep it dry underneath.
Since we fitted the water agglomerator, we have never seen a drop of water in there, 2 years+.
Sorry I didn't catch your reply earlier!
Peter
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Update for 2012:
Nuenen was a glorious hot weekend, good ferry trips both ways and the show was excellent.
here's a few pictures of the Ruston:
Running late on the Saturday evening, about 23.20:
(http://www.stationary-engine.co.uk/nuenen2012/Nuenen2012001.jpg)
Running in the daytime 1:
(http://www.stationary-engine.co.uk/nuenen2012/Nuenen2012064.jpg)
Running in the daytime 2:
(http://www.stationary-engine.co.uk/nuenen2012/Nuenen2012065.jpg)
It ran over the three days almost non-stop with no problems.
Peter
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Once again that is a gorgeous setup Peter. You were lucky to find that engine and it YOU !
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I agree Paul. What a masterpiece.
Bob
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Envy can be a cruel master.
WOW!
I'd be afraid to clean it as I might screw something up.
Casey
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Thanks, guys, it doesn't get spoilt, just a wipe over now and again, and the oil is total-loss anyway. We had fuel in from last year which we ran right out on the Saturday before putting fresh in.
It's surprising how many people don't twig how it starts up, they can't see a starter motor or hear anything whirring away, just a click from the starter solenoid and off it goes. We pull it backwards onto compression, then it has two turns to get up to speed before it fires.
We run 1kW of resistive lighting all day, that makes it nice and hot and keeps things from clogging up. The night-time picture was taken without flash, it was the load lamps that lit the engine.
Next outing is going to be at the end of the summer, we have two shows to go to, one at Barleylands in Essex, and the other is a very nice working weekend at Little Casterton, near Stamford.
Peter
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Rita got diagnosed with Cancer on our return from Nuenen, and entered hospital for a major operation just after that last post.
She is out of hospital now, and back at work but it was a scary time for us both.
We have been to Barleylands and Little Casterton shows, both nice long weekends, Thursday afternoon to Monday morning, so we could relax a bit!
Trailer and engine here at Little Casterton:
(http://www.stationary-engine.net/Forum/Images/Uploaded5/Casterton8.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded5/Casterton2.jpg)
Engine at Barleylands:
(http://www.stationary-engine.net/Forum/Images/Uploaded5/Barley1.jpg)
Probably the last shows we will do this year, and we have unloaded the engine for the winter.
We had a small issue of the engine moving on the chassis during a bit of repositioning, we tow the engine with the Discovery, but it put the drive pulleys out of alignment so we had to sort that out, but otherwise it was fine.
We are also running tea bags in the cooling water to stop rusting of the water jacket.
Saw this at Barleylands:
(http://www.stationary-engine.net/Forum/Images/Uploaded5/Barley8.jpg)
Peter
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We uncovered the engine after a fairly wet and cold winter, to have a look at everything and to check on the state of the batteries.
We didn't put any water into the engine, but cleaned up around the crankshaft ends and the cams, and gave them a good oiling.
It started first try, no messing about, just as if it hadn't been stood since mid-September 2012.
We are going to Nuenen in May, and we are booked into other shows for 2013. Rita's health is back to normal, so we shouldn't miss any shows this year.
The trailer is going to have some work done to it, the drawbar is being shortened by about 600mm, and we are fitting a new cross-piece into the chassis frame under the rear floor. The new trolley layout doesn't sit over the strengthened floor supports, and we noticed that the 21mm honeycomb was starting to sag under the weight, which isn't surprising!
It's only at the front of the trolley, the rear isn't affected.
Peter
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Fairly recent activity needs updating here:
The first thing was a second set of Bren Gun Carrier wheels that we bought in February, these got sent to Holland to be exchanged for another set with new tyres fitted on.
(http://www.stationary-engine.net/Forum/Images/Uploaded12/NewWheels1.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded12/RustonJuly3.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded12/RustonJuly4.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded13/RustonJuly6.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded13/RustonJuly7.jpg)
The set that came off will go for re-tyreing next year, but in the meantime they will go onto the Ruston Dynamometer rig, which we are just starting to get together.
Peter
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The drawbar trailer build from 2011 to 2013 has been put into a blog section on our websites, and has just been updated to bring it up to July 2013:
http://www.stationary-engine.co.uk/DBTrailer/DBTrailer1.htm
or on the USA server:
http://www.oldengine.org/members/diesel/DBTrailer/DBTrailer1.htm
Peter
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11/03/14
First run of 2014 today, I got the sheets off both Rustons and had a look at the wreckage.
Both survived the winter pretty well, a little bit of surface rust here and there, but the 1ZHR fired up on the button, no hesitation at all.
I took the trolley front axle off to replace the turntable screws that got sheared off last autumn when unloading the engine, Robert didn't realise that the turntable locking pin existed, and thought it just needed a hard pull, but he sheared the two M6 csk screws.
Replaced them with M8's and instructed both sons on checking that the pin was removed before they tried to steer the trolley.
The pin stops the turntable front wheels moving about in transit and allowing the straps to loosen off.
Tomorrow I have to fit the new deeper filter bowl and a new filter element.
All the electrics worked OK, just a good clean is needed then.
Peter
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Not quite as nice outside today, but the whisper of a bit of sunshine, so I had a quick lunch and went out to change the filter and water bowl on the 1ZHR.
Although we have never yet suffered with any water on this engine, I wanted a bigger reservoir so I could see it without the distortions of the smaller glass bowl, which has internal ribs moulded into its bowl.
Despite my taking some care over removing the old filter, it came away with a jerk and I splashed diesel over the chassis, but not too much, the drain container got most of it.
Old filter and bowl:
(http://www.stationary-engine.net/Forum/Images/Uploaded21/1ZHRFilter1.jpg)
New filter and bowl:
(http://www.stationary-engine.net/Forum/Images/Uploaded21/1ZHRFilter2.jpg)
Bled it and that was that. There was some very fine rust particles in the bottom of the old filter, probably from the tank, but no water at all.
Couldn't run it as the offices above me had their windows open, and although Leanne would close them if I asked, I don't need to run it right now.
Peter
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We took the Ruston and trailer up to Shildon in County Durham last weekend, for a vintage machinery show at the National Railway Museum (there are two, one at York, the main one and the other at Shildon which is the overspill site)
Weather was very cold with a bitter wind, the Ruston ran near 20 degrees (C) cooler than normal, but ran the whole day without any problems.
(http://www.stationary-engine.net/Forum/Images/Uploaded22/Locomotion01.jpg)
(http://www.stationary-engine.net/Forum/Images/Uploaded22/Locomotion18.jpg)
Another Ruston, this one is a 1HR, 5hp, the smallest of the range:
(http://www.stationary-engine.net/Forum/Images/Uploaded22/Locomotion08.jpg)
and finally a 1XHR, 8hp:
(http://www.stationary-engine.net/Forum/Images/Uploaded22/Locomotion09.jpg)
Peter
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I see these pics and I can't help but to say out loud ( Isn't this engine beautiful ?). It seems I am the only one in my house that has that reaction.
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Both the Rustons are up for sale, the 1YB has provisionally sold, the 1ZHR is still available.
Peter