ModelWorks Foden 
Builder's Diary

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Kit 2 - Front Axle and Saddle

Kit 1 account

Kit 3 account

:Thursday 27 April: After a 3 month wait kit 2 has been delivered.  

 
Contents of Foden Kit 2

The components of this kit were impressive and represent a considerable amount of machining by ModelWorks.  While all, except the saddle, are within the capacity of my machines it would have taken me several weeks to have  machined them.  The picture on the right shows a close up of the stub axle positioned with the main axle.

Following the lead set by John on his excellent Britannia site  I am marking more of my images clickable to reveal enlargements.  Simply click your back button when done.

The picture on the right shows a close up of the axle of a full size Foden C-Type lorry.  I have included this for two reasons, firstly it shows the differences in detail between the prototype and the model and secondly it shows the real life finish of the components.

Some of the components in this kit may appear rough but this picture servers as a reminder that much of this should be retained.

Reminder: Every single kit receipt will be required by the DVLA to establish the Foden as a new vehicle.

I made a start by cleaning up the saddle.  I used a old half round file to remove the shape edges and then went over it with a wire brush in the power drill.  I kept as much of the cast appearance as possible and severely radiused most of the edges.

In the instructions Steve indicates that it is possible to dismantle the preassembled leaf spring for cleaning.  I decided to do this but having done so I wonder whether it was worth the effort.  Some of the leaf springs were quite difficult to remove and I believe I could have done nearly as good a job with them in place.  Reassembly was easier that I expected as I found I found I could use the bench vice to compress the springs.

For holes I use a drill that has been wedged into a file handle.  

For edges and larger holes I use and old hacksaw blade that I have shaped into a knife.  I have taken nothing off the width and I periodically sharpen the square edges on the grind stone (I originally ground the teeth off).  As I drag one on the blades square edges along a sharp corner It shaves it off.

I totally endorse the instructions recommendation of using the pivot pin to ensure alignment of  the bushes.  I recall that on the Burrell's 2nd shaft I dry assembled the bushes and shaft and found everything in order but after I Loctited in the bushes I found the axle would no longer fit.  As a further precaution this time I oiled the pivot pin and left it in place as the Loctite cured. 

The thrust bearing for the sub axle is supplied in "kit form".  I found that the bottom bearing was not a sufficiently tight fit in the bearing shield to lock it in place so I used some Loctite. When I later assembled the stub axle to the front axle I discovered that the bearing shield rather than the top bearing made contact with the seat above.  I had not noticed that the height of the bearing shield was greater than the assembled height of the bearing.  Since the shield was taking the load I had no choice but to break the Loctite and reposition the bearing shield. Loctiting the lower bearing was a good idea but I should have trial assembled things first.
 

The bush welded onto the spring assembly needed quite a bit removed.  I tried to run a cheap 10mm drill through but this snatched and shattered - not a good idea.  I went back to using the round file and care was needed to avoid making the hole bell shaped.  ie the file must not be allowed to rock.

I have investigated using a trailer park but there is a waiting list and it is prohibitively expensive.  Since my garage has a relatively high ceiling my plan is to build a steel gantry and hoist the trailer to the ceiling.  So far I have completed an outline design that shows it is possible but I have yet to confirm the detail and order the steel work.  Until such time that I have completed the hoist I will not be able to paint or assemble the Foden.
 

This kit was much more interesting than the first and I felt I have done some real engineering.  As each section is completed a appreciation of the equivalent full size design is obtained.  In fact making a model can provide greater scope for getting to grips with the design than owning a full size.  

I am frequently asked "What is my Burrell for?" and the answer is "So that I can appreciate how they work".
 

The completed front axle prior to painting
 

The front spring needs to be returned for strengthening

Wednesday 6 Sept: I have just received an e-mail from Steve telling of the need to recall the front spring for rework.  Apparently the block at the top of the spring (see arrow) needs to be welded in place to provide a better load path.  As it currently stands the Foden's front weight  falls on a single M8 bolt.

We will shortly be receiving a letter from ModelWorks  asking for the return of the spring for modification.  In the mean time I shall remove the spring from the too be painted pile.

Painting of the front axle is described here.