ModelWorks Foden 
Builder's Diary

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Kit 11 - Cylinder Block

Kit 24 account

Kit 13 account

 
It might be a few days before I get round to photographing this kit and in the mean time
here is a picture of the cylinder block

Thursday 9th August: Kit 11, the cylinder block, was delivered today.  The kit also included the differential gears for the back axle.  While there is not much to be done with this kit the inclusion of the differential gears means that I can get on and assemble my Foden.  This is really good news and will keep me occupied once the rally season is finished.

Note: I second the note in the instructions concerning cleaning up the port faces.  It is import that they remain flat and excessive use emery paper etc can distort the ports faces leading to leaking valves.  This happened with my Burrell and I regret working the Burrell's port face to a mirror finish.

9th November: It has been months since I touched the Foden.  I understand that the cylinder accessory kit is in manufacturing and may be with us by the end of November.

Friday 23rd November: According to the ModelWorks website I should be getting the cylinder accessory kit by close of play today.  Just in case it does turn up I have cleared the table an photographed the contents of kit 11.

Contents of kit 11 - Cylinder Block
Note: this kit also included the differential gears for the back axle
 

Dent on cylinder end cover flange caused by careless handling during machining Machining marks on valve port Filing a triangular notch on the regulator port to provide a more gradual start Using a electric screwdriver to spin in the saddle's fixing bolts

Friday 21 December: With the arrival of the cylinder accessories I though it was about time that I attended to this kit.  I started by deburing and giving the block a light clean up.  I was disappointed to find two nasty dents on the bolting face for the cylinder end covers.  Judging by the marks they were caused by another cylinder block colliding with it as the blocks were stockpiled between machining operations.  There is not a lot I can do to fill the dents which are 10 to 30 thou deep however I am hopeful that the gasket will prevent steam escaping. 

I have had a lot of trouble with on my Burrell with a leaking regulator and I was determined not to repeat the mistake of over enthusiastic polishing of the valve faces.  In the process of bringing them to a mirror finish I manage to bow them such that steam can get under the valves.

I carefully removed the burrs around the port faces with a scraper.  I then got a flat metal plate (about 2 x1 1/2") and rubbed it dry across the cleaned port faces.  I did this without any grinding paste etc to avoid distorting the valve face; basically the idea was to take the initial wear that would other wise fall on the valve block.  When I came to the final valve face I was faced with deeper machining marks.  Rubbing my flat plate across the surface showed there to be a shallow trough and a sharp ridge.  Despite my reluctance to use wet and dry paper I decided to give it a quick rub with 400 grade w&d backed by my flat plate.  I shall postpone any more drastic action until after I have steamed the Foden and I can see if I actually have a problem.

There are various holes that have to be plugged in the block.  These holes provided access for machining operations and once plugged will form internal blind passageways within the block.  As the plugs were wound in they got very tight and I suspect the the holes are the tapered version of BSP.  The final task before attaching the saddle was to file a notch to provide a more gradual start to the engine.  I used the sharpest triangular needle file in my possession as I wanted the sharpest point possible since I suspect the engine will run on the merest pinprick of an opening.

The saddle is a separate component secured with 20 M8 cap head bolts to the block.    The mating faces are sealed with Foliac rather than a gasket and exactly the same technique was successfully employed on the Burrell.  After carefully deburring around the fixing holes I smeared the joint with Folic and began inserting the bolts.  I soon got bored with this and reached for the electric screwdriver.  Experience tells me that the Folic will ooze for the next few days and it will be necessary to retighten the bolts.

I plan painting the completed block as an assembly but before doing this I shall trial fit the cylinder accessories.  This is described in the kit 13 account.