ModelWorks Foden 
Builder's Diary

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Kit 3 - Rear Axleboxes and springs

Kit 2 account

Kit 10 account

 
Contents of Foden Kit 3

Thursday: The last thing I expected when the door bell rang was Foden kit 3.  I had already received two consignments of parts for my trailer lifting frame with the main steel work due tomorrow.  A quick read through the kit's instructions and check revealed that no Loctite 641 had been supplied.  Given the note warning against Loctiting the bearing until the axle is fitted I surmise that the plan is to supply the Loctite with a latter kit.  It should be noted that Loctite 641 has different properties than the Loctite 638 supplied with the last kit. 

Friday: Until I get the trailer out of the way I am not going to be able to do much with this kit.  Fortunately Parker Steel have just delivered my order and I will be able to make a start on the trailer lifting frame.  Before I do this I will make a start on this kit by cleaning up the components and trial assembling the axle boxes and springs.

Rear axle box

When I tried the slide the bearing into the axle boxes they would not go.  At first sight it looked as if the axle boxes had been bored undersize but this was not the case.

One closer inspection of the bore I could see that there was a burr and the bearing would not side in until I completely removed this using my deburring tool made from an old axle blade.

I threaded the springs onto the securing bolt but in order to get it to pass though the last  couple of springs it was necessary to compress the springs with a G-clamp.  I then realised I could position a pair of G-clamps to hold the springs in place whilst fixing them to the axle box.

I am a bit concerned at to the length of the M8  x 60mm bolts supplied.  When I fitted a bolt and fully tighten it I could only engage about two threads.  Ideally the bolt should have been 65mm, anything longer and it would interfere with the bearing.

I found using a wire bush in the power drill quick and effective.  I was quite therapeutic as the rust was replaced with a bright shine on the first pass of the brush.

Cleaning up the axle box required a combination of wire bush and file.  To get into the recesses I used a pointed wire brush.

Until mike pointed it out to me I had not noticed 

Fixing holes for Axle Box covers

that the fixing holes for the axle box covers have been "moved".  It looks as if the original holes were drilled and tapped in the wrong location, plugged and drilled in the correct location.  I am sure I would have done the same if I has spent hours machining the casting and discovered a mistake. 

I did not have the bolt done up partially tight and it is clear that with only 2 threads engaged the cast iron cannot take the load.  I strongly advise against using the M8 x 60 bolt to fit the springs and I shall be asking ModelWorks to supply a longer bolt.

That wraps up kit 3 and tomorrow I will start work on the trailer lift.

Thursday 29 June: Last week I received a mystery jiffy bag containing a couple of steel plates and bolts.  Whilst at the Tewkesbury Rally I was able to ask Steve their purpose.

Debbie is aware of this problem and we will be receiving our 4th set of bolts for the spring stack shortly.  

For a trial assembly was able to source a M8 x 80 bolt else where.  I found there was still a small gap at the top of the spring stack and have filled this with an offcut of aluminium plate.  The 80 mm bolt will need to be trimmed as it protrudes slightly into the axle bearing.

Painting of the rear axleboxes and springs is described here
   

The painted axleboxes and springs fitted to the chassis This nut will need locking

Thursday 21 September: Today I fitted the axleboxes to the chassis.  Assembly was straightforward but I had to keep my wits about me to make sure I fitted everything the correct way round.

I did not fully tighten the bolts securing the springs to the chassis as the bracket began to distort.  To prevent the nuts shaking off I shall lock them using Loctite but I shall delay this until after the axles and wheels are fitted.