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Thank you for delivering that message Mal, although Wade did leave a voice mail message on my work number but I was a little too snowed under to respond as promptly as I would have liked.

"I love deadlines - it's the wooshing noise they make as they fly past."

I will endeavor to give him a call tomorrow morning. Thanks again.

Friday 23rd July 2010

Drove the '41 down to the workshop and when I arrived what did I find Wade with? Why the fuel tank out of Big Red. Yesterday afternoon Wade had noticed there was a weep from the drain plug on the tank. Decided to fix it but instead of the plug tightening, the whole plug boss turned and a bigger leak immediately resulted! Out with the tank, a lot easier than on the Juniors we've pulled previously because the Senior tank has a straight filler neck not a curved metal filler neck. Once out Wade discovered it had been repaired before and not very well at that. So first up this morning we took the tank around to Emil, the local radiator repair guy, for repair work.

Then, as soon as we returned to the workshop, Wade received a call from Stan to say the new collar and the sleeved shaft for Big Red's water pump were ready. And because Stan is going fishing for a week we immediately went and picked it up. Back at the workshop the pump was reassembled with the interference fit collar pushed into the pump housing, the newly sleeved shaft and new bearings refitted, the ceramic seal fitted, the impeller fitted and then the pulley re-installed. The pulley itself is a big chunk of metal and it had been balanced with holes drilled around it's edge, and for it's size and weight it would need it!

Received a call from Emil to say the fuel tank was done and ready, so off we went again. Turns out the tank had been previously damaged and all around the plug boss it had been patched with body filler! Emil found this out when he went to repair the tank so had to remove all the filler first. Back at the workshop before re-installing the tank Wade commenced repairs on the fuel tanks sending unit. Although Wade had replaced all the wiring and ensured good connections it still read full on the gauge most of the time. Wade disassembled the sending unit, doing this by drilling out the three rivets holding it together to find a lot of corrosion inside. Now cleaned up but more to come, but it's certainly a whole lot cleaner than it was before. Wade's taking it home tonight and will use electrical contact cleaner as a further step in it's rejuvenation.

While Wade was doing that, I thought I'd get MBM into gear on the pumpkin to diff housing gasket for Noel's '39. How to do this though? The diff housing is still under the '39 so access there was cramped. However the pumpkin sent up by Peter Packard is still in the workshop so I eyeballed that. My eyeball observations were that it would need a gasket comprised of 2 concentric circles with a cut out for the oil drain hole and holes of course for the diff housing studs. Was able to turn the crown wheel so that a steel tape could be passed through the hemisphere allowing accurate measurements of both circles diameters. However didn't have a compass and Wade said he'd chased one before without luck although if he'd wanted he could have bought a full set of instruments in order to obtain the one he wanted, but passed on that. What to do? Why find something circular of the right, or close to the right diameter, to draw the circles required. Looked around and a couple of 20 litre drums, one plastic the other metal, looked like they'd be close. The plastic drum was too small but the metal drums base was spot on! So used that as a template and drew around it for the outside of the gasket. The inner circle was more of a challenge, but wandering around espied the hubcaps on Big Red. Fortunately with the front wheels off Big Red there was a hubcap readily available, and although the outside diameter was too great, the diameter where it tapered down to fit the wheel was almost perfect. Then followed some positioning jiggling of the hubcap inside the outer drawn circle and then by leaning the pen at an angle a line was drawn for the inner circle. Cut out the outer circle allowing a fraction more "just in case" and similarly with the inside circle allowing even more "just in case". Cleaned up the gasket surface of the pumpkin, which was mounted on some special Packard pumpkin stands, and a trial fit. Turns out the inner circle "just in case" wasn't needed and after a bit of pruning it fitted! Then using a small ball peen hammer knocked out the holes for the studs and the indentation for the oil drain plug. Then as I'm feeling quite pleased with myself, reality in the form of Wade intervened. Asked me about the crescent shaped cut outs for crown wheel clearance at top and bottom. They don't appear on the pumpkin but they are on the diff housing. So under the '39 with gasket and hammer and after some remedial work NOW had a MBM gasket for Noel's '39 diff. Wade rang about the pumpkin this morning but it won't be ready till late this afternoon so will be picked up Monday morning.

Quote: Matt for calling this morning, but referencing me to Wade as his secretary? I just try to help if I can! Pic's below of the engine and the bits and pieces that Wade rounded up yesterday.

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The industrious and generous attitudes of the gentlemen of 'Wades Workshop' never cease to amaze me! Thank you Wade (and Barry) for putting all of that together for me - I am very much obliged to you, although I hope your repayment, as discussed today, will go some little way in expressing my gratitude. And I really do mean that.

Also I am sorry, Mal, if my reference to your secretarial skills was in any way offensive, but I think it is important that, as a well rounded individual (insert smirk here), we are able to function in a number of roles. I think you should take it as a complement that I think you would make a fine secretary. Indeed if I may be so bold as to offer some advice for the future, I think that given your complexion you need to be careful in the selection of the shade of lipstick to be used, and maybe a little less blush would work better. Also you may want to consider leaving the fishnet stockings and suspenders in the drawer at home...

And I really DON'T mean any of that!

Thank you Mal for all your efforts here and your help to me personally. I always look forward to the opportunity of stealing a few minutes from work each day in order to check in on 'Wades Workshop' and I hope to catch up with you all again soon.

Hi Mal, can you elaborate on "On Tuesday Wade had taken the pumpkin to a diff company at Seven Hills for lapping-in and set-up." From a previous post. I am interested in what is meant by "lapping in". I have set up ring and pinions by means of getting the correct contact patch and backlash, but am unfamiliar with lapping the gears in. I am curious because I have a 3.92 set that I need to replace bearings on eventually and would like to ensure they run quiet and smooth.

Thanks!

Quote:Jim,

Quick google search found this series of videos.

Lapping in1

Lapping in2

Lapping in3
Quote:Matt,

You'll no doubt remember politician Alexander Downer and the fishnet stockings and high heels he donned for charity back in 1996, the images of which stayed with him throughout his political career.

Mal, thanks very much for posting the links. I have never heard of, or seen this process until your mention here. I will have to investigate and see if there is such equipment locally. I bet it makes for a very quiet fitment.

Jim

Monday 26th July 2010

Wade was working on Big Red's fuel tank pick up and sending unit when I arrived at the workshop. Had further cleaned it up, made a couple of gaskets and was now at the point of re-assembling it. Was able to provide the extra pair of hands required for putting the two pieces of the housing together and in the re-riveting required. Wade also soldered one of the rivets at each end to ensure a good earth/ground was established and maintained. Checks on the multimeter, during and after the re-assembly, indicates the unit should work well. After that came the re-installation of the tank itself back into Big Red. Lot easier than 120 tanks because it doesn't have the comparatively long and twisted filler neck the 120's do. Then came the reconnection of the fuel line, which was a different matter because of space restrictions not helped by the positioning of the auxiliary electric fuel pump. All back in now but the proof will be when the tank's refilled and is actually in operation.

Then a road trip out to Seven Hills to pick up the "lapped-in" and set up pumpkin for the '39. Back at the workshop came it's re-installation and re-assembly of the other parts. While the pumpkin had literally slipped out of the diff housing with nary a protest, reversing the procedure wasn't as easy. Pumpkin placed on a floor jack, slid under the '39's diff housing, then with Wade under the '39 manouvering the pumpkin/jack combination the fun started. Up a little, across a little, forward a little, down a little, across a little, back a little, forward a little, sideways a little. A little here, a little there but alignment and mating with the housing continued to elude us. At this point Graham wandered over and he was press-ganged into sliding under the '39 to assist Wade. Then with Graham's help, literally bench-pressing the pumpkin, it finally slid into position.
Graham!

After bolting the pumpkin in, came the re-connecting of the tailshaft to the pinion flange, cleaning and repacking the axle bearings, re-installing the axles, remounting the brake backing plates, re-installing the axle seals and retaining plates, remounting the brake drums, re-connecting the brake lines and bleeding the brakes. Probably missed something out my description of the re-assembly but hopefully in real life that didn't happen! All that should remain is re-installing the wheels/tyres then re-tightening the axle nuts once back on solid ground. The '39 will then be good to go!

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Mal, your documentary of the happenings at Wade's Workshop are eagerly anticipated. This is a rich resource of information that you are providing. Just a couple of comments about what I have observed in the photos on the last work on "Big Red".

I believe that there needs be copper gaskets between the differential housing and third member in addition to the MBM gasket. Maybe this was something that was done after 1939 to quench the leaking problem between the housing and the third member.

Also, and more important, I believe that there is no gasket between the axle housing and the brake backing plate. Shims to adjust axle shaft end play go here. A gasket needs to be between the outer oil seal retainer and the backing plate and a second gasket between the outer seal retainer and its outer housing or guard.

Just thought I would share this based upon my experiences. Please keep the documentary coming. Thanks. I see by my GeoChron that it is about 1315 on Tuesday in Sydney and 2315 on Monday here in Austin. Good night.

(o{I}o)

Wednesday 28th July 2010

Oil! Oil! That's the word that came to me driving to the workshop this morning. What was I thinking when I wrote - "All that should remain is re-installing the wheels/tyres then re-tightening the axle nuts once back on solid ground. The '39 will then be good to go!"? Before the '39 can go anywhere first the diff needs to be filled with a very vital lubricant! Fortunately Wade, as usual, was way ahead of me because on reaching the workshop there was a 5 litre container of oil on the bench. But unfortunately there was only about 1 litre in it! However Dave from Penrite is making a delivery tomorrow so oil will be well. Bad jokes aside I sprang, or rather slid into action on the creeper, under the '39 and put the litre we had into the diff. About a month ago I bought a cheap baster, just for these types of situations, after having to fill the diff in my '41 using a funnel, tube and small container. Filled the diff then but in the process spilled a lot of oil. Using the baster it's certainly a cleaner method but very slow, having to draw the oil in then push it out and repeat that numerous times. Just thinking, using a sports drink bottle with a flexible plastic tube might be even better! Hmmmmm......

While I was under the '39 Wade had taken out # 2 sparkplug, cleaned and re-installed it. He'd noticed there was a lot of gunk around the plug, appeared it may not have been properly seated. However Wade is suspicious because the plugs are NOS of unknown age and with time the seal between the porcelain insulator and the metal body sometimes fails. So after I finished under the '39 Wade started it up. And start it did, spun over very quickly on the now fully charged up battery coupled with the cleaned up starter motor. With the engine now running and the car up on jackstands the diff was "tested" by shifting the trans into top and letting the rear brake drums spin. Enabled the litre of oil in there to be circulated and could also listen for noises, of which there were none! # 2 sparkplug also appeared to be fine but will get a better test tomorrow when under load on the road.

Just as Wade switched Noel's '39 off, who should arrive but the man himself. Noel brought over the front shocks from his '41 160 Coupe which Wade had Tony "Shocks" rebuild last year. But they'd both sprung leaks so Wade will be return them to Tony for warranty repairs because they hadn't seen any service. Unless you count the 30' they'd travelled mounted on the chassis when being pushed around the yard. And Noel says he has some NEW Autolite sparkplugs which he'll drop in the next time he's over to replace the current plugs. Wade was happy to hear that. And then Noel said did you fix the welch plug? Blank looks on both Wade's and my faces then realisation that Noel was talking about the missing welch plug at the rear of the '39's OD that PeterL had noticed a few weeks ago when installing the DAF snubber. After Noel left Wade measured up the plug, in the tight confines under the '39 it looked about 17mm, then had a look in his stock. Plenty of bigger plugs but no small ones. However John managed to source a couple of boxes of plugs of various sizes, the smallest of which was 11/16 and of which there was only one! Fortunately it will fit. Using a bit more nous this time Wade measured the 11/16" plug directly against the plug in the spare OD, saved a lot of twisting and contorting. Fitment of the plug, which is now foremost in our minds, will wait however until the '39 can be put up on a hoist to give more reasonable access.

Yesterday Wade had picked up a couple of side mirrors to mount on Emily. Mount on Emily? What are we talking about? Emily is a '37 115c Sport Coupe owned by PACA member WendyS. Emily is coming into the workshop soon for a service, tune-up and general checkover all in readiness for the National Rally to Kangaroo Island in late September. The trip to K.I. from Sydney is about 1,400 kms, or about 825 miles. And all up, well over 3,200 kms or 2,000 miles will be covered, so mechanically the participating Packards need to be in good mechanical shape. Wendy's Emily will be followed in by husband Dicks '39 Convertible Coupe also for a service, tune-up and checkover in readiness for the rally. Now that's a Packard family for you! Mind you the '39 might come in before the '37 because those details haven't been settled yet, but suffice to say they'll both receive some pre-rally Packard TLC.

While Noel was at the workshop I returned a CD, he'd lent me a little while ago, of pictures from his Christmas with DAF. David, I'm tempted, very tempted, to publish a very candid shot of one DAF but, seeing I value my life very highly, have just managed to restrain myself from doing so. This is killing me......! What I will publish though are some Packard relevant pic's from a trip to New Orleans and Noel with couple of Packards.

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Thursday 29th July 2010

Yesterday, just after Noel arrived and the '39's engine was switched off, I said to Wade and Noel "What's that noise"? It was a glug, glug, glug sound and I was assured it was just the radiator overflow operating with the radiator coolant finding it's level after the 10 minute engine running time. This morning, Wade found a puddle of water under and in front of the '39. Seems the glug, glug, glug was actually a leak from the water pump. Preliminary investigation appeared the leak was emanating from the lower left water pump retaining bolt. However after draining the coolant, removing the fan and pulley then wrestling with the retaining bolts it was apparent the water pump seal was in fact the culprit. Just a word about the fan removal on a 120, not an easy job, the radiator fins act like an old style cheese grater with no regard for the frailties of human flesh! It's hard enough getting them out and when the time comes putting them back in is even worse! Did I mention wrestling with the water pump retaining bolts? I did? What happened there, was a 9/16" spanner(wrench) or socket was too small while a 5/8" was too big. What did fit was a 5/16" Whitworth spanner(wrench) or socket. But because of clearance issues with the front motor mount and the 2 lower bolts, that's where the wrestling came in. But with Wade's never give up, and if someone put it on I can get it off, attitude they eventually succumbed. Needless to say, these bolts will be replaced! Pump off, didn't look too flash inside and the bearing felt like it had lumps in it. Cleaned up, the pulley flange pressed off, impeller pressed off and shaft and bearing pushed out there was another surprise waiting. the impeller had been modified to accept a modern seal. While Wade had a "spare" impeller it was more decorative than useful having deficiencies of it's own.

Wade made some calls chasing parts and informed Noel of this latest "development". Noel, in turn, was soon in contact with a well known US Packard parts hound who just happened to have a NOS water pump on the shelf. This is now winging it's way across the worlds largest ocean to enable Noel's '39 120 to return to the road, it'll just be a little later than previously envisaged. While all this was going on David from Antique Tyre Supplies at Ingleburn, also distributors of Penrite Oils, arrived. David was delivering various Penrite oils to Wade, including the diff oil required for Noel's '39. David also informed me I hadn't paid for the bonnet(hood) welting, for the '41, I'd bought from him probably 18 months ago! And he's now promised to send me the bill! Isn't there a statute of limitations on these things? Now I think of it, I'd rung David about the welting and he'd posted it to me. Appears the accounting for it must have slipped between the cracks for a while. Meanwhile, Noel is apparently forming all sorts of conspiracy theories concerning this latest episode with the '39. Thinks I might be sabotaging it in order that I'll have something more to write about. I can assure you Noel, I didn't and don't do anything, these things just happen when I'm in the vicinity!

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