racer2_uk

1913 36 model 17 in the UK

Recommended Posts

Evenin Dwight,

 

Thanks for your interest in the Chalmers, the seat height and steering wheel position feels great, I have made the position a good fit for me at about 5'9", like you when I had a blank canvas I set things to my liking, I sat on boxes of different heights with the steering in various positions until I felt it was the most comfortable.

 

I would like to see how your car is coming along,

 

 

Andy

Share this post


Link to post
Share on other sites

Andy,

Good idea. I will do the same.

I will take some pics.  It is a rebodied '22  4cyl Buick. Most of the good parts are in boxes right now. Ebay is so good.

Share this post


Link to post
Share on other sites

Evenin,

 

another good day in the workshop, I removed the rod's, piston's, cam follower's and camshaft,

 

Chalmers%20008_zpspeoiqxis.jpg

 

Chalmers%20009_zps75ka5roj.jpg

 

Chalmers%20010_zpscfaalvxi.jpg

 

 

the crank journal's look good, just polished, the white metal is also good, only one small mark on one,

 

Chalmers%20004_zps1g52atow.jpg

 

Chalmers%20007_zps7hgaroxw.jpg

 

 

with the cam drive gear's removed the crank is now free to rotate without anything in contact with it, it has a rumble on the rear bearing with a slight amount of lift, I don't know if they are original but will be replaced,

 

Chalmers%20002_zpsiqajqy1f.jpg

 

 

more to do.

 

 

Andy

Share this post


Link to post
Share on other sites

Evenin,

 

 

Another week has gone by and more Chalmers engine parts are on the shelf, I made up a small puller and removed the starting handle dog and cam drive gear,

 

Chalmers%20001_zpsz4ajvmjz.jpg

 

 

I modified an old 2 leg puller to fit the flywheel, I then loaded up the puller, I wound it a little more and waited, then waited a bit more,

 

Chalmers%20003_zpssxxlaxyx.jpg

 

 

The flywheel didn't move at all, I decided to leave the puller on while working on cleaning up the crankcase and removing the black paint,

 

Chalmers%20007_zpsaosvmeck.jpg

 

 

After a couple of day's the flywheel was still in place, I didn't really want to heat it so another way had to be found,  I removed the puller legs from the holes in the flywheel, I rotated the flywheel until I found the bearing carrier retaining bolt's, these were removed and I made up a simple puller to pull the whole flywheel and crank assembly from the crankcase, this worked so easily,

 

Chalmers%20008_zpsecxfw19n.jpg

 

Chalmers%20013_zpsxudgicuu.jpg

 

 

The 2 crank bearing's sit in steel carrier's, the front carrier was able to move slightly to take up expansion, the rear was fixed by the retaining bolts I removed previously, now I can turn the bearing's by hand it is obvious they have to be replaced, I don't think they are original but are still very old and they are metric !    was this to take out wear with re-machining the carrier's or was this normal in the 1910's ?

 

Chalmers%20004_zpsosmzjgze.jpg

 

 

I now have the crank and flywheel assembly ready to take over to a friend's workshop that has a larger press than mine., I found the number 4 exhaust lifter had a small problem, the lifter is made in 2 pieces, the top adjuster block and the lower hollow cam follower, they are fixed together with a dowel pin, on this lifter the pin had become worn and had allowed a small amount of play "up and down", I have some steel rod of the same diameter and will make and fit another pin.

 

 

Andy

 

 

 

  • Like 1

Share this post


Link to post
Share on other sites

Evenin folks,

 

 

I took the crank and flywheel assembly over to the big press, firstly we put the flywheel on the press with the crank hanging below, we used a dial indicator positioned on the centre boss to check for deflection when under load, as soon as the press ram touched the crank end the dial moved, when the lever was pumped a little the dial really moved round, something was wrong, we then made up some steel blocks to locate the load right on the back of the bearing rather than the flywheel, this time the ram pushed down and the indicator hardly moved and the crank steadily came out, when we looked at the rear of the flywheel we could see the reason for the deflection, there was a crack running around the centre boss ! this looked very old and was dirty and oily, definitely nothing recent and maybe something to do with the vibration.

 

Chalmers%20006_zpsavmzgmzt.jpg

 

 

The rear bearing carrier came off without any trouble and the axial play in the single row self aligning bearing was evident, the front single row standard type bearing also came off easily with a lot less play than the rear, the rear carrier has a very nice multi plate oil seal arrangement next to the bearing, it is amazing to see how much play there is in the bearing's after feeling very little when the engine was fully assembled.

 

Chalmers%20011_zpsvhyy9bne.jpg

 

 

The crank looks good, I will now mount it on centre's and check to see if it is bent in any way,

 

 

Chalmers%20012_zps6wbiosia.jpg

 

 

The double keyway's are a very nice touch,

 

 

Chalmers%20015_zpsbqsslyqt.jpg

 

 

I will now draw up the flywheel and get a new one machined from steel which will be a lot stronger.

 

 

Andy

  • Like 1

Share this post


Link to post
Share on other sites

Evenin everybody,

 

 

The cracked flywheel is away to be copied, it will be in steel and should be ready at the end of January, the replacement crank bearing's have arrived,

 

Chalmers%20001_zpsfoj8vefs.jpg

 

 

The water pump occasionally let out a drip so I had decided to strip and rebuild it, it came apart easily and the magneto drive side bush was a little worn, it pressed out and I was able to clean up the pump castings,

 

Chalmers%20008_zpsmfibl5wz.jpg

 

 

A new bush, seals, taper pin and a gasket and it will be ready to pump again.

 

On a slightly different note I have been able to find a brand new "KLG type F15" spark plug for my Napier Lion aero engine, I never thought I would find a spark plug that rare and old still in its box !

 

Chalmers%20005_zpshwz1ydb0.jpg

 

 

Andy

Edited by racer2_uk (see edit history)

Share this post


Link to post
Share on other sites

Evenin everybody,

 

Apologies for the lack of updates on the Chalmers, festivities, birthday's and general life has just got in the way,

 

I have spent a lot of time on the water pump and pump drive, I rebuilt the pump,

 

Chalmers%20002_zpstthnfz3g.jpg

 

 

I then checked out the alignment of the pump shaft from the drive to the magneto shaft with a turned alignment shaft,

 

Chalmers%20002_zpsuhvlxuye.jpg

 

 

I found that the pump location diameter was different than the mounting location by 20 thou, the pump had been clamped previously by the small grease seal pad, this has now been shimmed and the pump shaft is now aligned.

 

 

I have also made a new drive coupling that will allow a tiny amount of misalignment and still give me timing adjustment.

 

Chalmers%20pump%20drive%202_zps2iurcha2.

 

 

Hopefully I will get back to normal and get a bit more done.

 

Thanks for watching.

 

 

Andy

Share this post


Link to post
Share on other sites

Hi JFranklin and all,

 

Thanks for your kind words JFranklin, its a lot of fun and bloody annoying,

 

I have got a bit more done, I have made up a bigger diameter fuel line from the fuel cut-off valve forward to a point were I can make up a final section to link up to other carbs in the future, I have stripped and regreased the steering column and adjusted the bearings,

 

Chalmers%20002_zpsrgd8t4i1.jpg

 

You can see an earlier repair on the control quadrants,  the road springs have been removed and delivered to the spring specialists where the rears will get more lift and the fronts will be made equal height !

 

 

Chalmers%20005_zps0cij4fik.jpg

 

 

while the springs are off I am making and repairing some spring hangar pins and have some laser cut shackles being cut ready for machining,

 

 

Chalmers%20006_zps96qt09ti.jpg

 

 

Andy

Share this post


Link to post
Share on other sites

Evenin everybody,

 

I have been doing loads of thing's to the Chalmers but haven't seemed to have got anywhere !

 

I have fully machined and fitted the new front spring shackles and pins, the springs should be ready to collect from being height adjusted for the rear's and the fronts equalled up,

 

 

Chalmers%20002_zpsuacgkeih.jpg

 

 

I have cleaned up the rear axle mounting to the springs, I also machined a slot to hold the bolt head when tightening,

 

Chalmers%20005_zpsqx6cr0hp.jpg

 

 

New rear spring bolts are ready to fit along with the spacer plate's to give more clearance between the brake tube and the spring's,

 

Chalmers%20008_zpskr3uxgh3.jpg

 

 

Amongst many little jobs like making up some brass fitting's on a new fuel pipe to allow different carb's to be fitted, making new spring hangar bushes and painting bits and pieces, I managed to make up a new sump gasket,

 

Chalmers%20007_zpsvhompsna.jpg

 

 

I managed to get hold of another Splitdorf model X magneto last week, although various shipper's, carriers and distribution companies had the opportunity of a game of football with it along the way,

 

Splitdorf%20004_zpsoeve25f4.jpg

 

It is a shame a couple of useable part's are broken but I got a perfect distributor spinner, point's and arm assy, brass cover and most of the rotating part's, even getting the carbon's was good.

 

I hope to get the spring's this week and then the flywheel, should be a bit more going on soon.

 

 

Andy

Share this post


Link to post
Share on other sites

Evenin everybody,

 

 

I collected the springs, turned a couple of new bush's and with a bit of elbow grease they were fitted,

 

 

Chalmers%20005_zpszjzsoc3k.jpg

 

Chalmers%20006_zpsfpinzfhh.jpg

 

 

 

I am particularly pleased with the front spring hanger's, they have turned out very well but took a lot of machining from laser cut blank's,

 

Chalmers%20014_zpsnvoo3jya.jpg

 

 

I have also refitted the rear axle torque arm, when the previous owner changed parts of the car the torque arm was one of thing's he modified, I have refitted the front location point allowing it to work properly and look a bit better than it was, I also un-seized the main pivot pin, the top pivot had it's seal missing and so water and time did the usual,

 

Chalmers%20008_zpsdhlmon2b.jpg

 

 

Chalmers%20007_zps1chtnkew.jpg

 

 

All the spring pivot's have been greased and split pinned, the axle mount's went straight on and are now moving freely with no play or binding, later this week I am going to visit my local crank balancing guy to find out what can be done and if his machine can take the weight of one of these old crank and flywheel lumps.

 

 

Andy

Share this post


Link to post
Share on other sites

Afternoon everybody,

 

I must apologise for the lack of updates, the delay with the flywheel has been annoying to say the least but I can tell you it has now been machined and has only the keyway to be cut and then I will have it ready for it to go to the crank balancer !

 

In the meantime have a look at this lap from last year's Cholmondeley Pageant of Power, the Chalmers didn't get the fastest lap !

 

https://www.youtube.com/watch?v=_8EZvS9gvUI

 

 

Andy

Share this post


Link to post
Share on other sites

Afternoon everybody,

 

I had a crash course in soldering last week and have started on a couple of repair's on the fuel tank and radiator, there were a couple of damp patch's around the drain point and the end's of the tank seam,

 

Chalmers%20008_zpsmollhmgd.jpg

 

 

Chalmers%20006_zpsr5gji3bc.jpg

 

 

The radiator outlet had a very slight leak which turned out to be a tiny crack in the brass, to make a good repair I have got to get the area level as the area was pushed in somehow, I have made up a frame to position the brass face ready to solder a new strengthening piece in place,

 

 

Chalmers%20004_zpsy9hxezdp.jpg

 

 

I have just finished a small repair on the cooling fan mounting, the shaft is located with 2 flat's, these had worn over the year's and didn't lock in properly, this is now fixed.

 

 

Chalmers%20003_zpsovcic5ec.jpg

 

Hopefully a flywheel update will be here soon !

 

 

Andy

Share this post


Link to post
Share on other sites

Evenin everybody,

 

As the supplies and various bits and pieces I needed for the radiator repair arrived I was able to make a brass strengthening plate to cover the small crack, give support and a flat face for the outlet elbow,

 

Chalmers%20002_zpsreuwsdpu.jpg

 

 

it all went together well and will hopefully be a good repair,

 

 

Chalmers%20007_zpsoz3v17bk.jpg

 

 

Chalmers%20011_zps0syo4fzb.jpg

 

 

I am pleased with the result's of the soldering, many thanks to Chris Williams (Napier Bentley) for the crash course in soldering and the loan of tools.

 

I have made a fuel tank drain plug because when the area was prepared and the old solder removed I realised that a brass disc had been soldered onto the outlet boss instead of having a plug fitted !  this one is an aluminium plug, it works well but I might make a brass one.

 

 

Chalmers%20004_zpstvrfwqot.jpg

 

 

 

Andy

Share this post


Link to post
Share on other sites

Evenin all,

 

I have spent some time on the propshaft, I stripped it down and found 1 dry joint with a bit of wear, I turned up a couple of new bush's and it is ready to go,

 

Chalmers%20008_zpsxc22ieoe.jpg

 

 

Chalmers%20009_zpsuutl7qjk.jpg

 

 

Now the big news ! 

 

The flywheel is done and is here !

 

Chalmers%20001_zpsslxrigh0.jpg

 

 

Chalmers%20002_zpsuvelh1mp.jpg

 

 

I have to refit the clutch location's and clutch stops and then I will get it pressed on the crank and they will go away for balancing, then the work start's !

 

 

Andy

Share this post


Link to post
Share on other sites

Evenin everybody,

 

More flywheel and crankshaft work done, I refitted the clutch location post's and went around to the agricultural engineer's to press the flywheel back on the crank, their press has a wide bed to take the flywheel with the crank hanging below,

 

 

Chalmers%20001_zpsyq3tubbq.jpg

 

 

Chalmers%20005_zpsnvdh2xqg.jpg

 

 

Chalmers%20003_zpshhechzhr.jpg

 

 

The new flywheel fitted perfectly and the locking nut and spring loaded detent pin went together easily, on Monday I will drop off the assembly at the balancer's.

 

 

Andy

 

 

Share this post


Link to post
Share on other sites

I am impressed by the quality of your work and think it is great that  you are documenting it all for us to see. Is there a Chalmers club ? Your car must be 

the best maintained of any existing examples. Well done. 

Share this post


Link to post
Share on other sites

Mornin Barry and all,

 

Thank you very much for your kind words, it is appreciated, I really enjoy all aspect's of having the Chalmers, it has common sense engineering and is a hoot to drive, as you can see I am not a polisher but a user and all the work is really to get it back in a condition where I can have the fun with a little less time in the workshop in the future.

 

There seems to have been a club in the not to distant past but due to someone passing it no longer functions, here in the UK there seems to be 4 examples, 3 being 4 cylinder car's and 1 a 6 cylinder, also another 4 cylinder car in Germany.

 

Thanks again Barry.

 

 

Andy

Share this post


Link to post
Share on other sites

Evenin everybody,

 

The crank balancer has done his work, thanks Mike Huddart, I collected the balanced crank and flywheel this morning and got straight into preparing it for the press, first off is the flywheel, then pressing the front bearing on the crank, then the rear bearing onto the flywheel and lastly the flywheel back onto the crank, this all went well, thanks Andy Roycroft.

 

 

Chalmers 006.JPG

 

I made a set of lifting chains and got the crank assembly lifted up ready for the crankcase to be positioned underneath,

 

Chalmers 007.JPG

 

With a little gentle persuasion the crank was back home,

 

Chalmers 010.JPG

 

The whole assembly was now lifted onto the engine stand ready for the long hour's to commence,

 

Chalmers 013.JPG

 

 

Andy

Edited by racer2_uk
no photos showing (see edit history)

Share this post


Link to post
Share on other sites

Evenin everybody,

 

A quick update of the progress in the last couple of day's, the camshaft, timing gear's and follower's have gone back,

 

Chalmers 001.JPG

 

 

Chalmers 007.JPG

 

The small brass block on the side of the crankcase is the air pump and non-return valve for the fuel system, the oil pump was also refitted and primed.

 

The engine is starting to look good with the clean alloy and brass.

 

 

Andy

 

Share this post


Link to post
Share on other sites

Evenin everybody,

 

After a late start I got on quite well today, I re-fitted the pistons and prepared the block base and crankcase top,

 

Chalmers 004.JPG

 

everything went together as planned,

 

Chalmers 009.JPG

 

the engine stand I originally made when rebuilding the Napier Lion engine makes working on any engine a pleaseure and allows you to get all round the engine with ease,

 

Chalmers 011.JPG

 

Chalmers 013.JPG

 

Chalmers 015.JPG

 

The gearbox went on with a bit of a fight as lining up a centre bearing, 3 clutch location posts and 8 mounting stud's is almost too much, the engine and gearbox are now ready to drop into the chassis,

Chalmers 020.JPG

 

I am going to sleep well tonight !

 

 

Andy

  • Like 1

Share this post


Link to post
Share on other sites

Evenin everybody,

 

I did sleep well !     so after another late start I got to work,

 

Chalmers 001.JPG

 

The engine and gearbox dropped in easily, the engine mounting bolts were refitted, tightened and split pinned, I had to check the alignment of the pulley's and slightly modify the dynamo position, this did need doing a long time ago !

 

Chalmers 006.JPG

 

The air compressor drive gear, coupling, water pump and magneto all went together after having spent a lot of time on them when I reconditioned the water pump, the exhaust downpipe located itself when I lowered the engine in, I was watching the mounting positions then realised it was fitted !

 

Chalmers 007.JPG

 

More sleep needed.

 

 

Andy

  • Like 1

Share this post


Link to post
Share on other sites

Evenin Dwight and everybody,

 

Dwight, I am pleased to know it is not just me with the sleep thing !

 

I got another good day on the Chalmers, I fitted a lot of the plumbing and improved on a couple of area's including a proper carb warming system and an oil filter, I have to test that the pump is up to the job of overcoming the filter back pressure, currently the pump only scavenges from the sump and via a dash glass returns the oil to the conrod dipping channel's in the sump top,

 

Chalmers 003.JPG

 

 

If the filter works I will modify and paint up the mounting plate,

 

Chalmers 002.JPG

 

 

Starting to look something like now,

 

Chalmers 004.JPG

 

Now, about that sleep,

 

 

Andy

Share this post


Link to post
Share on other sites

Evenin everybody,

 

Today was very productive and the Chalmers has come together well,   lots of plumbing for the carb heating which I haven't had working before, I fitted the prop shaft but had to drop the torque arm to lower the diff flange a little as the prop shaft wouldn't compress enough to clear the pinion locknut, as soon as I did this everything bolted up,

 

Chalmers 004.JPG

 

After adding engine, clutch and gearbox oil's, lot's of water in the radiator, attaching the battery and a couple of gallons of petrol it was time to try the engine, after making sure the ignition was on full retard and the fuel was through to the carb I tried the starting handle, on the second pull it fired up and sat at a high idle with very little dripping on the floor !

 

Chalmers 012.JPG

 

I made a couple of small adjustment's to the idle speed and the mixture and then backed the car out into the sunshine,

 

Chalmers 005.JPG

 

After a few minutes warming up I drove up and down the lane to get a feel of how the winter work had changed thing's,   the steering is a bit tight, the clutch needs adjusting and I need to check the air/fuel ratio,  the main thing is after all the work and new flywheel the engine feels smooth and responsive.

 

I hope the weather will warm up a bit before I venture to far.

 

 

Andy

 

 

 

  • Like 1

Share this post


Link to post
Share on other sites

Create an account or sign in to comment

You need to be a member in order to leave a comment

Create an account

Sign up for a new account in our community. It's easy!

Register a new account

Sign in

Already have an account? Sign in here.

Sign In Now