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Sunday 12th May 2013

Mother's Day today here in Oz. So why was I working on the Coupe this afternoon? Because our family celebrated Mother's Day early, on Thursday with our daughter and her three children and Saturday with our two sons, their wives and a granddaughter. This gave everyone a free run with the other parents and grandparents today and gave us a free day. So, after catching up with some Packard club work in the morning, turned to a sadly neglected Coupe in the afternoon. And why neglected? Because since the body and paint repairs, before the National Rally in March, the Coupe has been devoid of it's right side fender spears. I needed some new wire clips and screw fasteners to reaffix them because a fair number broke or were missing on disassembly. Picked up some of the screw fasteners from eBay, then recently Noel donated about a dozen used wire clips. My list of excuses for not doing the reinstallation was getting considerably shorter. And why on the lawn? Because 1) not enough room in the garage, it's a tandem, and 2) the driveway is slightly sloping and rough. So onto the grass, well a fine mix of disparate grasses and weeds really, under lovely sunny autumn skies and away I went. Most of the rear fender spears fasteners were the screw type while the front spears were mostly wire clips. Because I wanted some positive fastenings on both sets of spears I shuffled clips and fasteners between front and rear sets so all spears had at least three screws on each spear set. The new screw fasteners have a wire spring which required some massaging in order to enable them to slide into the backs of the spears. Most of the time spent was with these fasteners bending the wire so it would fit in the groove. Then it was just a matter of positioning screws and clips, bearing in mind the orientation of the spears, and pushing them into place. But I also found I was short nuts or fasteners for the screw type fasteners so I'll chase those later this week. Another thing I must do is find a rear fender spear to replace the bottom spear because it's longer than the others. I didn't notice that until, about 6 months after I bought the Coupe, Wade pointed it out!

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Wednesday 15th May 2013

Returned to the workshop today to find it looking like a sawmill, part of Wade's floor area was covered in sawdust and offcuts! Chris, Starliner, had been over yesterday and fabricated a floor and a back for The Fossil's boot(trunk). Wade had previously spoken to the 'chippy' aka carpenter, in the business next door, about doing this but it never happened. Into the breach stepped Chris who has the requisite skills and it's obvious the chips did fly. Well the sawdust did, even though Wade tells me Chris has dust catchers on the power tools used! So after sweeping the floor, and some clean up of other areas, that floorspace was once again ready for work. Pity about Fleurette though, because all the carpentry took place right behind her, she now has a layer of sawdust gracing her once immaculate lines. And the reason why the sawdust was there this morning? They finished at 7:30pm last night!

Turned then to cleaning some parts for 1) Fleurette, 2) Big Red, and 3) The Fossil prior to their being painted by Wade this afternoon. Harvey arrived a little later armed with parts for 1) Wade, a '37 Super 8 front stub axle, upright and brake drum and an exhaust pipe for same and also a radio, 2) Me, a pair of used(well used) Willys hubcaps and a Jeep distributor. Actually the '37 Super Eight parts are for Peter Packard via Wade while the Willys and Jeep parts are for the father of a guy living in Perth, the father and his '38 Willys are actually in South Africa. The guy in Perth had gotten onto me when I placed a want ad for Harvey on the AACA Site for Willys hubcaps a couple of years back, because his Dad only has three hubcaps and needs a fourth. Now he has five, albeit some in less than Concours condition!

Backtracking to Monday, at the start of a day in which Noel and I drove to checkout a possible venue and facilities for the siting of the next Australian National Packard Rally in 2015, we first called in to see Noel's Coupe. The panel shop was virtually on our way to our destination and Noel needed to check something with Karl, the panelbeater doing the work. It turned out Karl wants to see my Coupe again, mainly to check out the bonnet(hood) mountings. I'll now be driving it over there tomorrow morning for Carl's scrutiny. While, tomorrow afternoon, the plan is to return Roy home to Richard and Wendy.

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Thursday 16th May 2013

Started the day by installing nuts onto the many bolts holding the right mudguard(fender) spears to the Coupe. Then with the spears secured it was off to meet Noel and from there onto the panel shop and Noel's Coupe. There Karl inspected the bonnet(hood) mountings, props and a few other aspects of the front sheet metal to aid in reassembly of Noels Coupe. Noel is pleased with the progress Karl is making on his Coupe as each time he visits something more has been done. This apparently is in stark contrast to Fleurette where, from the sounds of things, it was an ongoing battle to get things done by the panel shop doing her!

Later, back at the workshop, caught up with what Wade had been doing to The Fossil where the boot(trunk) lid has been receiving attention so the hinges can be remounted. Also saw the rear floor heater outlet after yesterdays paint and it looks good. Yesterday at Lee Bros, besides the nuts I picked up for the Coupes spears, I purchased 2 longer coach bolts for mounting The Fossils Trippe Lights. But discovered today they are slightly larger in diameter than required. The coach bolts that came with the Trippe Light brackets are 4"(100mm) x 12mm while the replacement ones are 4&1/2" x 1/2"(12.7mm) That 0.7mm does make a difference. So tomorrow, after visiting grandkids, I'll exchange them for a pair of 4&1/2" x 12mm coach bolts. I'll also be picking up quantities of 8/32 and 10/32 bolts, nuts and washers for The Fossil at the same time.

Then it was time to take Roy home. This was easily accomplished with Roy running really well, keeping up with traffic wasn't a problem. Wade wanted to know, once we arrived, what his speed was along Mona Vale Road. Had to tell him to relax, the indicated 60 mph was in fact about 80 kph or around 50 mph! Obviously Roy's speedo is very optimistic. After delivering Roy to the comforts of home turned to Emily and made her day by fitting a replacement left outside door handle courtesy of Noel's US connection. Little bit of a struggle to do so until it was figured out the bezel went on one way, the other way changed the handles orientation to the door skin!

Returning to the workshop, I drove the Ute for a change, reason being Wade wanted to thaw out! Wade had driven Roy with the top down, being a Convertible Coupe, but for reasons other than asthetics. With the top up, the mail box slit like rear window doesn't afford much visibility at all! So with the top down, especially combined with Sydney's autumn weather, the wind chill factor was readily apparent. Also, on the way back, called into the auto upholsterer working on Big Red. The guy had worked on the front seat, especially the drivers side, to repair worn areas. He'd salvaged pieces of seat fabric from under both the front and rear seats to be able to effect the repairs needed. Looks good! I aim to take the Coupe there next week for a quote to repair the torn, frayed and split front seat. Depending on cost might also be looking at new kick panels and maybe a new carpet!

And this just for Noel - All going well, Graeme Wilkins expects to have the work on Fleurette's engine finished on Tuesday.

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Monday 20th May 2013

Drove the Coupe to the workshop today because 1) I'd lent my other car to my sister, and 2) I wanted to get a quote for recovering the front seat of the Coupe. Mission accomplished with front seat squab and backs to be recushioned, resprung, especially on the drivers side, and recovered. Sarkis, the upholstery guy, is also going to make and fit a new carpet front and back. In order to get matters under way Sarkis removed the front seat squab and both seat backs replacing them with a temporary drivers seat composed of blocks of foam. Not pretty, but they did the job, and the extra elevation provided the best driving position I've had in the Coupe!

That done, at the workshop, spent a lot of time cleaning paint and rust off Fleurette's tappet covers, timing chain cover, front engine plate and front motor mount. In the course of doing that, all in preparation for their repainting in the near future, saw a problem with the timing chain cover. In fact I'd finished cleaning it to almost within an inch of it's life when I realised it didn't have a life! What I thought was a spot of gasket cement was a small hole, but at least we now know the source of an oil leak. 282 waterpumps have a weep hole that is directly over the top arch of the timing chain case and that's where the hole was. I'd noted there was a rusty section at that point but hadn't noticed the hole. And now I know why the bottom of Fleurette's rebuilt waterpump had a build up of grease and dirt. It was directly above the hole in the timing chain cover. Wade thought he had a spare on the shelf, Old Blues original cover, but it couldn't be located. Instead turned to JohnM's '39 Six engine which has been sitting in the corner since a rebuilt engine was swapped into it a few years ago. John's engine has been a source of a number of parts since then so has certainly come in handy. Of course it also meant I had to completely clean the cover from scratch, but that's life in the world of Packards.

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Friday 24th May 2013

Q - If I said the stories stemming from the title of this, so far on-going, saga are drawing to a close what would that mean? A - It would mean that Wade's occupancy of his "Shed", aka workshop, will cease in the near future. Wade is moving house, next week, heading about 120 kms North to live on the western shore of Lake Macquarie. As such Wade's occupancy of workshop space at West Ryde will come to an end. However the house Wade is moving to has a 9m x 9m shed where he still will be able to play with Packards to his hearts content!

Earlier this week, Amelia was relieved of her engine in preparation for a move of her own to a panel shop, and that move occurred today. At the panel shop Amelia will receive a full body makeover, as and where required. While that is taking place, Wade will be disassembling Amelia's engine at Lake Macquarie and rebuilding it so that they can be reunited later to make Amelia complete again. Also, earlier this week, received a care package of parts off US Ebay where a recent seller had numerous '35 parts on offer some of which Amelia required, see pic's.

Wade has been packing in preparation for the move North but this hasn't encompassed the workshop side of things, that'll come later. He's been concentrating on the house move, more specifically the contents of his "other" workshop. This other workshop was in the garage and encompassed Wade's other hobby, electronics, and needed to be boxed up and/or disassembled for transportation North. The major part of the disassembly were the benches and shelving units, set up and built into the garage. Wade has accomplished all that but the removalists aren't tasked with their transportation, that Wade is doing himself. To that end the workshop's car trailer is being utilised, because the carcasses for the benches are quite large. And, because the trailer needed some TLC, that was done yesterday, with a new hitch and brakes being attended to. The new hitch and 2 pairs of brake shoes had been purchased on Wednesday in preparation for the work required. However the brakes needed more than new shoes because the old shoes were down to the metal, no lining left at all, and had ground or should I say gouged the drum surface with a lip about 3/16" deep on the edge of the drum preventing their easy removal. Fortunately Harvey's heavy duty brake drum puller, used on many Packard rear drums, helped overcome this impediment. At that point it became evident more than replacement shoes were required so these were returned and complete new backing plates, shoes and drum assemblies including new wheel bearings were obtained instead. Today helped Wade load the benches and shelving on the trailer and, on the trip to and from the house, Wade commented a number of times about how well the trailer pulled and stopped now. Packed and ready to go, the trailer will head North early next week in conjunction with the house move.

There's also things happening with Fleurette, the block, crank, etc being picked up from Graeme Wilkins late this afternoon. There'd been a delay in the crankshaft grinding which pushed things back from an expected pickup on Tuesday. And, speaking of pickups, I'll be running over to Graeme's early next week because the valves were somehow overlooked in the pickup today! There was also a dropoff earlier this week with Thelma's carburettor being left with Carburettor Service Company for rebuild. Will take about 3 weeks because Tim is presently away for 2 weeks so the carb will be attended to on his return. But back to Fleurette, on Tuesday Wade will start the engine re-assembly, while on Wednesday Noel will be slapping Bill Hirsch Packard Green on the block, head, etc. All going well, Noel should be behind the wheel of Fleurette for our Packard run to Eden, about 480kms South over the weekend of 7th - 10th June. Also, when Noel dropped into the workshop yesterday, he compared some replacement hubcap clips with those already on Fleurette. He's had problems because his clips have lost tension and aren't retaining the hubcaps like they should. Still has problems because the replacement clips, which were supposedly longer but weren't. Because I have a spare set of wheels I also compared the clips on my wheels with one of Noel's replacement clips and they too are the same.

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Tuesday 28th May 2013

Today Fleurette's engine started to come together. Arrived to find Wade was just finishing cleaning the block. First step after that was cleaning the cam followers and re-inserting them. Next was pre-lubing the cam bearing journals and installing the cam. A new retaining plate was installed together with re-inserting the little plug, also retained by the plate, at the front of the oil gallery. But there was some consternation before the new retaining plate was installed because it couldn't be found! Here I have to confess it was ALL MY FAULT, isn't that right Noel? I'd inadvertently put the box it was in, along with some other parts, in with Ross's parts. Took a fair little while before we found it. A new rear plug completed the cam installation process. Once that was done the main caps came off, they'd been tunnel bored, the bearing shells inserted, also suitably treated with pre-lube, caps installed, and torqued to the Packard recommended 82-85 ft/lbs. It never ceases to amaze me that after torquing the caps down the crank turns easier than before being torqued!

Then we had a visitor, Noel! An unexpected pleasure but there was a reason for Noel's visitation. Hub cap clips! Noel had been referred to Helm Springs as a possible maker of the springs he requires to secure Fleurette's hubcaps. Apparently DAF had previously supplied longer springs which are now ensconsed on Fleurette's rear wheels and Noel required a sample for Helm's to work from. Jacked Fleurette up removed a rear wheel which Noel took away and TonyW drilled out one of the hubcap clips retaining rivets. Noel returned with wheel and freed hub cap clip. There's quite a difference between the two clips, see pics. Also had a call from Sarkis, the upholsterer who is redoing the front seat and carpet of the Coupe. I'd taken the Coupe down to Sarkis yesterday, because he'd finished the front seat bottom and backs, and now wanted the Coupe so the front seat frame can be taken out to enable measuring for the new carpet. Sarkis's call came at an opportune time today in that I was able to get a lift with Noel to his shop, saved me a 5 minute walk! And the reason Sarkis wanted to see me? He'd hung the Coupe up in reverse gear! Although I given him instructions I obviously didn't stress the necessity for only gentle shifting between gears, thinking that he was only going to use 1st and reverse didn't warrant such a warning. Easy fix, under the bonnet(hood) and showed Sarkis how to align the bell cranks, but also stressed the necessity for gentle shifting.

Back at the workshop, next was installing the pistons to the rods, then the piston rings and the rod and piston assemblies together with new bearings and pre-lube into the block where they were married to the pre-lubed crankshaft. From the box of DAF replacement rods the first one selected was #6, then into the box of pistons where #6 was located. The rods had looked sh#thouse when received, rust pocked externally, and still look so. But surprisingly.......all the piston pin bushes had less than 0.001" wear so, instead of being rebushed, were left as is. Of course the rods were checked for straightness, etc and the tunnels rebored as well as being balanced. Next was rod #7 and piston #7, then #2, then #3, then #7!!!!!! Wait on, we've already done #7! Much confusion, much checking of numbers on rods but no clarification. Hmmmmm......something's not right here. Putting the second #7 aside, then did #8, #5 and #1 without further dramas and returned to the evil twin #7. #4 piston was still waiting to be united with a rod so at least that was clear. Pulled the #7 we did earlier and minutely examined the numbers stamped on the rod and the rod cap and they all certainly looked liked #7's. Except, these old eyes, finally found the merest hint on the rod cap that it was a #4 and not a #7! Removed the #7 piston from the #4 rod and putting the rod aside used the remaining rod clearly marked #7 instead. Then #4 rod and piston were united and installed. End of story? Not quite! #2 compression ring ring on #6 had been installed upside down, not noticed until we were doing #7's piston rings. From #7, or should that be #4, it all gets so confusing with all these numbers flying around, all #2 compression rings had been installed right way up. So, it was back to #6, out with the rod and piston, removed #1 and #2 compression rings and re-installed said rings before #6 went back in the engine again. After each piston and rod assembly was installed there was a test rotation of the crank to check all was well. And it was, even with the #7/#4 fiasco, although the more assemblies added the harder it was to turn, everything still turned smoothly.

Yesterday, besides taking the Coupe to Sarkis, I'd gone over to see Graeme Wilkins and picked up the box of errant valves not collected last Friday. Then tomorrow, with Wade physically moving into his new home on the Central Coast, Noel and I will be painting Fleurette's block, head, bellhousing, tappet covers, etc, etc with Bill Hirsch Packard green engine paint. Later tomorrow I will be taking Fleurette's exhaust/intake manifold assembly to Reconditioning Services at Auburn for the manifold to block surfaces to be resurfaced. Today we'd mounted the manifolds on the bare block and bolted them together with a new gasket before tightening it all up. On the way back from the manifold resurfacing will drop into Pirtek at Rydalmere for a BSPT threaded plug for the rear of the oil gallery, could get very messy very quickly otherwise.

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Wednesday 30th 29th May 2013

With Wade moving today, Noel and I had Packard corner to ourselves for the painting required. On my arrival moved some of the stuff that has accumulated in the last couple of weeks so I could set up the windchimes again. Then cleaned and blasted a few parts, also re-blasted a few of the parts from last week where they were lightly rusting. Then Noel arrived, a final clean down of Fleurette's block and Noel stirred up a 1/2 can of Bill Hirsch Packard green engine paint. However Noel passed on the 1/2 can, it was too old with a skin and lumps on it. Fortunately Noel had a second unused newer can of Bill Hirsch Packard green engine paint and that was quickly brought into play. While Noel painted the block I strung up the parts for a Fleurette windchime. As Noel finished the block I gave the head a final clean and painted it, then cleaned up the top and lower parts of the bellhousing and set Noel to work on those. While Noel was engaged with the bellhousing I started on the stuff strung up on the windchimes and moved through those until Noel advised he'd finished. Dug out the water pump and harmonic balancer which Noel painted while I continued on the windchimes. Finishing again, set Noel up with the sump(pan) to which he gave a final clean and then painted. Finished the windchimes and checked around for parts missed, finding the oil pump and the thermostat housing, another final clean and they too received the royal order of the paintbrush.

That done then journeyed around to see Sarkis and the Coupes re-covered front seat bottom and backs. A good job except.......what was supposed to be a colour(color) match for my present upholstery, wasn't! Still, being the grateful recipient of the donation of the broadcloth in question I couldn't complain, could I? And I learned something today from Noel, he was telling Sarkis that the wool used in Packard's broadcloth was all sourced from New Zealand. Noel also suggested I recover the rear seat to match the front one, but financial considerations stand in the way of that at present. Not to say it won't happen at some future time. Noel also took the opportunity to enquire whether Sarkis could repair the hole worn on the right side of Fleurette's front seat caused by the handle of the seat adjuster wearing against and through the fabric. The answer was in the affirmative, as you'd expect, so Noel and I retraced our steps and returned with the seat bottom 5 minutes later. Of course the broadcloth is a better match to Fleurette's fabric than mine, but that's life. Noel also asked Sarkis to sew a leather patch over the outside of the new fabric to minimise seat adjuster handle wear from here on. Fleurette's seat will be ready on Monday. Never know, Sarkis could find himself sewing up a complete new interior of a certain '41 160 Club Coupe down the way a bit! He's already earned brownie points, in Noel's judges eyes, by the way the seams in my Coupes front seat bottom line up with the seams in the seat backs.

Dropped back at the workshop by Noel, picked up Fleurette's intake/exhaust manifold assembly, and headed to Reconditioning Services at Auburn via almost the full length of Silverwater Road. The intake/exhaust manifold assembly will be ready to be picked up mid Friday afternoon. Then it was back down Silverwater Road, again almost it's full length and turned of to Pirtek for the oil gallery plug. Except, Pirtek doesn't carry plugs of the type required, but referred me to Cedrays at Silverwater. Silverwater? Yes, Silverwater, had to travel almost the entire length of Silverwater Road again. And good thing I'd been to Cedrays before with Wade, although they have a frontage to Silverwater Road, entry is from the street at back. There, in trying to explain in my fractured way what was required was invited around the other side of the counter to help peruse the shelf items without success. However, armed with a description of what was required my, as I came to know him, good Samaritan counter man sought advice from others and determined what I wanted was a grub screw! Of course, that's it, a grub screw! Was even able to find one in the required size, being 3/8" BSPT. Even better my good Samaritan counter man gave it to me - gratis, free and no charge! Probably cost more in time and effort to write it up than it was worth charging for. Then, for the last time today, again traveled Silverwater Road, this time it's full length, because that took me almost all the way home.

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Never heard of or saw a GRUB screw.
My education continues!
Thanks Mal.

Friday 31st May 2013

Yesterday Tony from Reconditioning Services rang to say they were having difficulty setting up Fleurette's intake/exhaust manifolds assembly for the surfacing. Wanted to know whether it would be OK, if necessary, to weld some nuts to the end of the manifolds so it could be set up and also whether pickup on Monday or Tuesday would be OK instead of today! Although I was very reluctant I agreed that he could do what was necessary for the setting up, but........damaging the manifold wasn't acceptable and to err on the side of caution. Also, Monday was the latest that it could be ready. So this morning, because I was concerned following Tony's call yesterday, again travelled the entire length of Silverwater Road(Noel, you're lucky I'm not charging by the mile!) to see Tony. Tony was down the back of the very long workshop and when he came up, before I could say a word, said "it's finished"! And there I was ready for battle, had even brought a copy of a pic I'd taken of Tony with my manifold assembly back in 2008 to show that it was possible. Plus, if memory serves me right Jeff, PAC052, had his even longer 288 intake/exhaust manifolds assembly surfaced there a year or two back and they did it while he waited. Tony took me down to see the manifold assembly, still set up in the surfacer, and I showed him the pic taken 5 years ago. Tony's hair has greyed somewhat since then and because of that took another pic of Tony, pointing out this physical change, together with Fleurette's manifolds. Left very happy with the manifold assembly in the boot(trunk) but only travelled about a 1/4 mile when I received a call from Tony. They still had the studs and fittings taken out of the manifolds so they could be set up in the surfacing machine! A quick u-turn, back to Reconditioning Services where Tony met me at the front of the driveway, collected the studs and fittings and off again down almost the entire length of Silverwater Road and from there off to the workshop.

At the workshop, after unloading the manifold assembly, first things done were disassembling Fleurette's engine parts windchimes and putting away those and the larger parts painted on Wednesday. Noel, there will have to be some touch up, but overall turned out not too bad at all. Then, because I'd said in an earlier post that we'd found a can of POR 15 Black Velvet exhaust manifold paint, Noel had expressed a preference for the exhaust manifold to be painted with that instead of the POR 15 Manifold Grey I'd used a while back. Noel, as they say in the classics, your wish is my command. But, on trying to open the can of POR 15 Black Velvet, found the lid was rusted to the lip of the can. Not a good sign to start with, and on opening the can found very solidified paint. But it did mix in reasonably well, although there were still large lumps left! Tested some on the old cracked manifold off Fleurette and it looked OK, so pressed ahead. By the time I left, the parts of the manifold painted first had started to dry and looked greyish. So there must have been still plenty of black pigment left in the lumps. Don't worry Noel, a fresh can of POR 15 Black Velvet should be available from Brookvale on Monday if needed. And speaking of Monday, Noel is coming over to the workshop then to pick up Fleurette two front wheels. He'll then take them so TonyW can mount the long hubcap clips Noel had made up by Helms Springs, and which he picked up today.

Then, on the way home, because my drive takes me past Sarkis's upholstery shop, I saw the Coupe parked with the front poking half out of the shop. As is my want, I stopped to take a pic, but was spotted by Sarkis who called me in. He was in the midst of installing the new carpet and had called on George, the mechanic in the shop next door, to give him a hand to lift the front seat back and bottom assembly back in. Although I offered to help, George and Sarkis did the lift while I snapped a few pic's. Plus, Fleurette's worn through front seat squab side had been replaced and reinforced with a strategically placed leather patch. And, if all goes well, the Coupe should be ready to come home late this afternoon. I'll also pick up Fleurette's front seat squab and return it to the workshop where it can go, no, not in the front seat, but in the backseat and out of the way until the engine is back in.

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Friday 31st May 2013(Part 2)

All went well and, with no phone call from Sarkis to say he hadn't finished, arrived to find the new carpet in, front seat frame bolted in, seat squabs and backs in place, new kick panels in, the new door sills I'd bought at Hershey last year installed and the fire extinguisher now mounted upright on the right side kick panel, before it had been mounted behind my feet on the floor. And an unexpected bonus, a strip of leftover carpet edge bound and almost the width of the new carpet and the depth of the flat front floor area on top of the new carpet in the front floor area. But not enough time to take pic's of all this, with sunset approaching. I'll catch up later if that's OK? Also took Fleurette's front seat squab round to the workshop. At the workshop, surprise and it was a surprise, found Wade busy at work reassembling Fleurette's engine, hadn't expected that! But Wade wasn't happy, because some of the valves won't fit the now K-Linered valve guides! He'd put a call into Graeme and was now waiting for a reply. Wade's intention is to work all weekend, if possible and if necessary, to get the engine back together and into Fleurette. But, before I left home, found I still had a piece of Fleurette in my daily driver! One of the studs off the intake manifold for the carburettor was lying on the passengers front seat, must have slipped out of the envelope containing them when Tony gave them to me earlier today, it's now back at the workshop.

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