T. Green No. 2135 - latest report
T. Green No. 2135 -latest report
On Sunday 9th May 2010 2135 was prepared for a full steam test and road run.
After much work over the winter the engine sounded much better but final timing was still necessary.
We took the roller for a test run of about half a mile, the engine sounded OK, but the gear train was more than noisy and the vibration was horrendous!
And so it was back to the yard and back to the drawing board.
Here we had a conference on what should be done. We decided that the gear train needed to be stripped down and assessed, and repaired as necessary.
And so on Thursday 13 May we started to strip the gear assembly.
Firstly let me explain how we thought that something was amiss.
After the primary gears and selector had been repaired, changing gear was very difficult, this we assumed was that it needed 'running in', but we now know better.
The primary to secondary meshing was too deep! More about that later.
After removal of the ash pan, for 'jacking purposes' the engine was jacked and supported with timbers, for safety, the wheel hub cap removed and the pin and sleeve removed in readiness for rear wheel removal.
This done and the wheel rolled forward and tied off for safety.
We then proceeded to remove the gear guards and put in the barn out of the way.
What greeted us was horrendous.
The differential spur gear was 85 thou loose on the bevel gear shaft, this sleeve bearing was later found to be the original and was already worn out. After removal of the differential spur gear, (laid flat on a pallet) it was found that the 'new bevel gear', which is the drive to the roller was loose on the drive shaft, was later found to be 15 thou too loose! (Should be a 'drive on fit',) and could be pulled off easily and the flat bed keys just fell out! Should also be a tight fit. These keys had had some weld added and filed to 'fit' but were 100 thou too loose!
So together with the diff spur movement and the bevel gear and keys moving, the gear teeth have suffered, and will also need redressing.
So now to the secondary shaft, this was also too loose, both play in the sleeve bearings and laterally (side to side), of some 80 thou and 185thou. Respectively.
This shaft was then removed, for bearing replacement.
So correct gear train meshing could never have been attained, with a combination of incorrect sized bearing, or worn bearings or incorrectly fitted bearings and keys!!
Also to add to the problems, the main drive bearing support casting, which has taken the brunt of this vibration, is cracked, (this has been braised before!), I may however get away with this as it is, we think, supported adequately. See enclosed photos.
So in short the mechanics of this beautiful rare engine have been a total 'Stuff up'
And have caused me a lot of work and some considerable expense, and it hasn't stopped yet!
My biggest headache is to reduce the bore of the bevel gear, this I intend to do by having it's internal diameter chrome plated and reground to fit, plus new keys.
I don't want to have to have a 'new' gear cut, as that would really cost.
As you can imagine this work, could take me the rest of this years rally season, mainly because I am at the mercy of specialist engineering services, but when completed and the engine timing finally done should give me a good mechanically sound engine and roller.
I will then need to have it boiler tested for another year.
In conclusion, so far, I think that the 'Restoration, mechanically' has been very suspect, but at the same time a steep learning curve for me.
Photo gallery

































































































































