Lister 5/1 Diesel

Ruston-Hornsby 1ZHR

Rebuilding the Ruston - Page 9


More on the beast today:

We had to extract an old 1" BSP stub from the cylinder head, without doing too much damage to the head in the process. Previous attempts with various devices had just left a crushed pipe, which wasn't very good quality or very thick wall.

In the end we hacksawed the stub off, and then using a long thin chisel, collapsed the remains of the stub into the hole, and then ran a plug tap down the threads to clear out any rust.

The top connection had a new gasket made from Hallite, and then it was cleaned up and put with the other bits ready for painting.

Then the paint brush came out and we put a first coat onto the fuel tank, and after some 'will we, won't we' thoughts, we painted the water tank as well. That is brushing cellulose so will need 24 hours to dry before we can rub it down for the next coat.

The photography flatters my handywork, there are some paint runs in there! The stainless steel hose clips turned up in the post today, surprised but pleased to see that they are very good quality and have the BSI Kite Mark stamped on them, makes a change from cheapo Chinese stuff.


03/04/2010 Continued

I cut two lengths of 3" rolled steel channel before tea, and had intended to get them drilled etc tomorrow, but there wasn't much doing generally at home, so I walked back up to the factory after tea/dinner and got them both sorted out.

The channels support the Start-O-Matic alternator, and also provide for belt adjustment for the two V-Belts that drive the alternator from the layshaft under the engine, so 3" slots were needed, 1/2" wide or clearance for 1/2" bolts.

It's 1/4" thick in the centre of the channel, so no chance of punching it out, so a series of holes were drilled and then cut through the remains with the disc cutter.

Filing isn't my favourite job, but with a couple of big sharp files, the job was done quicker than I had expected. The edges were cleaned up all round with a couple of Swiss files, and that was it.

I'll get these mounted tomorrow, and the we can get the alternator up onto the chassis frame to see about belts etc.



Back to the grind!

Got the new channel sections out and drilled the main frame to take them, did a trial assembly with the SOM alternator, and decided that I didn't like it there, so moved it across a bit and tried again, that looked much better!

Usually, if it looks right, it is right, and that proved to be the case.

Put a third coat of varnish on the engine cushion, fed the nags and came back home for a couple of hours. Going back later to put some more paint on the tanks after a quick rub-down (tanks that is, not me!)



One idea that has been buzzing round my head for a few days, is to fit a larger alternator, to give the Ruston more load. One that is available is the EDC 3.5kVA unit that isfitted to the two Coventry Climax gennies that we bought some years ago.

These are very similar to the Lister unit, although without electric starting facilities.The pulley would need changing to a 2-row, not a big deal, and there is 12V battery charging built in.

Condition is quite good, and we have a choice of 2 to select from. There is also one on ebay at present if anyone wants one (not one of mine)


05/04/2010 Continued Various jobs to sort out today, the second coat on the water tank looks fine, the fuel tank is a bit lumpy, and we are not that keen on the colour either, so we will get a match done against the engine paint tomorrow to make it look right.

The engine bed was prepared and fitted this afternoon, had a few issues with through-bolt cleances, but nothing too serious.

Got the alternator off the frame so the mountings can go away for shot blasting etc., took the opportunity to paint the missed bits on the front of it, and gave the pulley/flywheel a rub down and coat of undercoat.



More work on the lump:

Rubbed down and repainted the two tanks, fitted the inlet/outlet spouts on the water tank, fuel tank needs another coat yet.

Also repainted the water outlet

Another shot of the tank, no hold-down brackets or rods on yet.

Also got the ring oiler back on the crankshaft and the timing gear cover refitted. Hopefully we won't need the crankshaft removing for a while!


10/04/2010 More today, need to speed up a bit as May is getting closer!

First job was to get the water tank up and installed, any number of new coats of paint won't make it work any better, and we had the pre-formed 90 degree hoses arrive this morning, still awaiting the short-delivered 45 degree bends.

Riveted the holding-down brackets on, and it went up quite well. The bottom hose was able to be finished, just needs some Boss white jointing compound on the threads into the engine.

The bottom hose connection was quite straightforward, just a 90 degree and 45 degree bend and a 4" piece of stainless tube plus clips.

The tie-down rods and brackets worked fine, decided to leave the rivets in natural rather than paint them.

Had to open up the decking by the drive pulley to clear the V-belts, that was a hydraulic punch job which didn't take too much time, but we had to take the decking out to cut it. Haven't bolted it all back together again in case more adjustments are needed! (No picture of that)

Then we revisited the battery tray, and now we have the missing top cover, we were able to make up the two M8 stainless studding retainers, and check that it all worked OK. Two pieces of 8mm PVC sleeving were slipped over the studding to tidy it up.

The thick rubber matting we originally used was changed for some thinner insertion sheet rubber, and once we had punched holes to clear the holding down rods, it fitted nicely.

The fuel tank is almost there, 5 coats later! :whistle:

The weather was so warm today that I decided to try thinning the paint a bit, and it seemed to work out OK. The tank looked better this coat, although we are obviously building up a decent thickness as we go along.

Last job of the day was to start rubbing down and painting the main drive pulley, which is about 30" diameter. There was a jumbled bit of lettering on the side of one of the spokes, which was the pattern number, but full of casting sand! Once we had cleared all the sand away, the number was perfectly legible.

Originally blue, now Bronze Green.

Nearly 10 hours work today, all doing fiddly bits and helping Philip with his Landy as well.


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