ModelWorks Foden 
Builder's Diary

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Kit 12 - Brake Accessories

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Kit 23 account

The contents of Kit 12

Thursday 1st March: A card from City Link awaited me when I returned home yesterday.  Since the last time I have been "carded" the system has changed and I had to call their automated telephone system to arrange redelivery.   I found this longwinded though I must have punched in the right options as the parcel arrived today.  The kit consist of the brake master cylinder, brake pipes, parking brake, cab floor and front mudguards.   While most of the braking system has now been supplied there are a few essential items still to come.

 

The handbrake operating mechanism

Monday: Today I tackled the handbrake operating mechanism.  After cleaning up the support bracket I spent some time polishing the operating handle to a pleasing sheen.

The brake operating bracket supports the steering column support stanchion.   The instructions suggest fitting the mechanism to the chassis with the bolts loose and tightening them so as to leave the steering support correctly aligned with the column.  Unfortunately I found on tightening the bolts that +the steering jammed.  To investigate the route cause I removed the bolts holding the steering support to see where it wanted to go.  I was expecting to find the angle to be wrong but was surprised to find that the problem was horizontal alignment.  To line up the brake bracket would need to be moved towards the centre on the chassis by 4mm.  I considered ether bending the steering support or increasing the clearance for the bolts so that the brake bracket could be slid into alignment.  In the end I decided the easiest remedy was to "move" the mounting holes for the steering support.  It only took me a few minutes to plug the existing holes, drilled and tap replacements.
 

I though the existing welds were enough but having been told they were not I formed a continuous fillet along the entire length of the seam.  In doing so I made a whole lot of trouble for myself as the fillet prevented the step fitting.  I should not have put any weld near the step fixing holes.  I had no alternative other than to grind out some on my weld.

I now suspect that my floor was originally welded correctly as there were several 3/4" long decent fillets around the edge of the floor.  I might be worth contacting  ModelWorks before sending back the floor.

On the plus side I was able to get on and trial assemble the floor and mud guard to my chassis.

Friday: I need to get this kit out of the way so I can get "Little Beastie" ready to steam on Monday.  I shall be attending a celebration in Dartford Central Park on Saturday 17 March to mark the unveiling of a blue plaque to Richard Trevithick.

After gluing the brake band using contact adhesive I improvised this clamp to hold it together whilst the glue dried

This kit included a longer replacement brake band to replace the one supplied with kit 4.  The kit did not include replacement rivets for the guide bracket, F40522 ,  but fortunately I had not already used these.

The brake lining has to be fixed to the brake band using contact adhesive. As the contact area is large, contact adhesive is strong enough to provide the braking force but I do not think it is able to prevent the ends pealing back.   I know a number of Burrell constructors, including myself, whose brake lining unwound from the lining. I believe this occurred when the end of the lining became detached and was pulled around by the brake drum unzipping the lining.  Rather than wait for this to happen I decided to rivet the ends of the lining using brass tacks in the same way as I fixed the Burrell.