Lister 5/1 Diesel

Ruston-Hornsby 1ZHR

Rebuilding the Ruston - Page 6

09/07/2009

Couple more bits that we have been working on:

The starting fuses for the engine are fitted into a screwed holder, which is inserted into the head before cranking the engine.

As our engine is ex-technical college, it also has fittings for an engine indicator, which complicates matters somewhat. There is a big casting that screws into the head, and into that go the Dobbie McInnes valve with the tapered seat on top, and the starter holder which screws underneath.

We will have to remote the indicator as it is far too big to fit in its old position:

So we are fabricating an adaptor that will enable us to take the indicator instrument away, and also we will replace the starter fuse system with a glowplug that can run off the batteries. This will need much less space around the cylinder head area.

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11/08/2009

This caught my eye on Fleabay last week, and after a brief wait it was ours to collect. The main attraction was the fact that it would fit on our trailer without too much work, and had brakes and steering already in place.

The Ruston & Hornsby 1ZHR trolley chassis will drop straight onto this frame without any mod's, and we already have some wheel rims and tyres to suit, plus it came with a spare wheel. There is some rudimentary rubber block suspension on the axles, but the travel is very short.

The last image is what the trolley was used for originally, it is a mk7 Air Conditioning Set, used on Hawker-Siddeley Trident aircraft.

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16/08/2009

Stripped the towing hitch down today, got it dismantled and cleaned up, gave the steering a grease as well.

The blocks of steel preventing the suspension moving were interesting, there's about 1/2" or so of movement available, but the steering tie-rods are so close to the chassis, that the rods foul the chassis members if the suspension moves more than about 1/4", not a terribly good design!

The front towing drawbar design leaves a bit to be desired as well. It's all well made, but the main pivot pin relies on the two side pivot points for bearing area and they are not greaseable, while the pin itself has over a foot of available bearing area in the main swivel housing, and could have had a grease nipple fitted. It's so bl**dy obvious you wonder what the hell the designers were about.

Got to cut some channel tonight to provide mounting points for the Ruston chassis. The Ruston flywheels are about 34" diameter and the centre of the crank is 18-1/2" above the mounting point, so no clearance issues.

Pictures below of the shortened chassis, one of the rear axles showing the small gap allowed for movement and the front axles blocks that we removed.

Got a length of 4" channel cut up tonight on the old Rapidor hacksaw, 2 pieces 21.75" long to bolt to the trolley, then the Ruston frame can sit directly onto it. Might be able to get a chequer-plate decking underneath to hid all the axles etc., although I quite like the look of the trolley as it is. We have some more of the wheels and tyres knocking around, we saved them from Elstow Storage depot near Bedford when it closed down. The wheels were stripped and repainted, the hubs are down in the workshop still and the tyres are out back.

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17/08/2009

Having cocked up on the frame width details, I cut another pair of mountings this morning, and got them drilled tonight on the Elliott Progress 3A. The drill at the factory is not really man enough for heavy work.

Looks fairly in proportion, no big issues, except that the rear mount will have to have the bolts set into tapped holes as I cannot get under the chassis rail due to the suspension cover being there.

The last picture shows the horizontal pivot that I was on about previously, that bar just sits there, the drawbar pivots on the last 1" at each end, instead of using the whole cross-piece as a pivot and fixing the ends of the drawbar to the bar.

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18/08/2009

We have to get the workshop cleared a bit because of a job coming in, so I got the trolley chassis and mountings sorted out and drilled today, it all fits surprisingly well and a piece of chequer plate will be put over the central section to cover up the chassis underneath.

We used doubled-up M12 bolts for the channels to the bomb trolley and four single M12 for the engine frame to the channels. Pictures of the bolted down lump below.

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18/08/2009

More work this morning and evening, I got the Ruston main lump out of the workshop and after a lot of humping and grunting it was up on the trolley frame again and the whole thing back onto the trailer.

The rear engine mounting hole was already in place, but the two front ones remained to be marked and drilled, so I spun the engine round (slowly!) on the chassis and got the two 20mm holes drilles and deburred. Might need to adjust the back hole by a bit as we seem to be out on what the Ruston factory drawing says and what our engine holes are.

The front bolts are over 300mm long, so will probably use some threaded M20 bar which we have plenty of.

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18/08/2009

Had to work yesterday, but had a good session on the Ruston today, getting the crankshaft and flywheels back on the engine so that the drive layshaft position could be sorted out.

One unusual thing with all the Rustons is the length of the overhanging pieces of the crankshaft, the pictures show this well.

The drive layshaft is provided to give a proper ratio for the engine to drive the Start-O-Matic alternator, and also in reverse to start the Ruston up. Other things are the rev-counter belt pulley that needs sorting out.

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