This is my current project, started in August 2014. A John Smyth Faultless engine serial number 106,203, 4 1/2 hp. this is a Waterloo manufactured contract engine. There is severe rusting in the bore and it really needs sleeving. This is a problem in view of its long stroke, 9 inches, requiring a 14 1/2 inch long sleeve, not easy to find.
Ready to start
The engine stripped ready for work to start.
Head damage
Frost damage to head that needs brazing
Muffler
New muffler completed, made by shaping filets of steel then welding.
Gudgeon Pin
The gudgeon pin was replaced in view of the intense pitting. The bronze beaing was also worn out of shape and a new one was machined.
Worn Gears
The two gears were badly worn in places, some teeth being eroded to a knife point.
Crank Gear
The new crank gear cut from a billet of steel. The stud for the other gear was also replaced, being made oversize to compensate for truing the hole in the eccentric gear.
Cart
Completed cart with home fabricated wheels and iron work.
Fuel Tank
Fuel tank made from a boiler pressure vessel. Holes were welded and new flat seam made as well as adding filler cap. Clamp style stand then made like original photos.
Sleeving 1
Boring cylinder for sleeving. Cutter head mounted on boring bar a 1 metre length of 32mm precision ground steel. The plate clamped to the cylinder head is centred on the bore and provides support for the 2 precision ground guide rods.
Sleeving 2
Gear box made up using lathe change gears. This reduced the motor speed to the 150 rpm and provided scope to change gears and adjust the speed.
Further gears and the use of a threaded rod produced a cutter feed of approx 2 thou per rev. The rear bearing for the boring bar can be seen, this could be moved on the guide rods enabling the boring head to be accessed to adjust the cutter and measure the bore.
Sleeving 3
The complete set up. A plate and bearing are fitted at the crankshaft end to support the boring bar. After boring the sleeve was press fitted, bored then honed 10 thou undersize so the oval piston could be trued.
the piston ring groves were trued and new rings and spacers fitted.