Overhaul for Puddle Jumper.

shaun · #1 24-12-11, 01:57

After 11 years on the road and covering a minimum of 300 miles a year i thought it was time for a major strip and inspection of my No2 Mk2* Novembe 1944 universal carrier (Puddle Jumper as its know to many). It has had the standard pre season service each year and a few major services but now is the time for a really good go through. I have already taken off most of the access covers and pannels etc to copy for my MK1 project so it half way there already.

The many years of going to the War and Peace show has ment there is dust in every where, as well as a build up of dirt and some rust under fuel tanks etc.

The engine and transmission are still in good order but now has a few leaks etc which will now be fixed. the sprockets are just showing the signs of ware but nothing major yet. i have a really good set of track to fit once all is done.
The only damaged part so far is the cush drive between the fan and dynamo , which has for some reason broken up. But having made one for the MK 1 i know it is not a hard peace to reproduce.

So first things first, a good pressure wash , btu that will be next week. I am posting some photos of the strip down and areas not oftern seen as well as a bit of detail.

enjoy !

shaun · #2 24-12-11, 02:00

More photos

shaun · #3 24-12-11, 02:03

more photos

eddy8men · #4 24-12-11, 11:09

good luck with it mate, i hope it all goes well.

rick

kevin powles · #5 24-12-11, 13:50

Shaun, after christmas would like to do the right hand exhaust downpipes before you swing the engine out, have six flanges made, others to finish or buy, think second week after christmas would suit...........what you think?.

kev.

Phil Waterman · #6 24-12-11, 16:58

Hi Shawn

Please keep us posted on the progress of your overhaul. One work of caution about "overhaul" of a running vehicle, it will take you longer than you would like. Having said that there have been a number overhauls and restorations shared on MLU in the past and I am amazed at the rapid progress some people have achieved.

So Merry Christmas Happy New Years, and best wishes that you will be once again enjoying driving your Puddle Jumper again soon.

Cheers Phil

shaun · #7 26-12-11, 12:44

Phil , Thanks for your reminder of time scales. its so easy to take something apart more than is intended. My aim is to have PJ back on the road for the end of January so i can get on with the MK1. Basically its a strip , inspect, repair and repaint.

Kevin, That time scale sounds fine, im not going to pull the engine out of PJ so it will not be a problem.

I hope christmas has gone to plan for you all and you have had a great time and eaten way to much -i know i have !!

shaun · #8 28-12-11, 00:37

do you remember i said in my last post the engine was not coming out , well change of plan - it is. Got to do it properly . There is lots of muck every where from years of driving. the diff has most of beltring and Holland stuck to it i think.
One of the brake linings is near the rivets the others are all fine, but i will get the full set relined. no other major problem so far ! he are some more photos.

RichardT10829 · #9 28-12-11, 00:40

teaching the master to suck eggs here but .....Shaun make sure you either mask up or hose the brake drums down..that there dust be a killer matey

shaun · #10 28-12-11, 00:41

more photos - a mouse had made a nest near the cam plate - that is a weel traveled nest !

shaun · #11 28-12-11, 00:44

one more photo, engine out tomorrow. Then a pressure wash through.

shaun · #12 28-12-11, 00:46

Thanks Richie, yeah they are old linings. going to wash them with the hose when she is pulled out of the workshop.

shaun · #13 28-12-11, 22:29

the engine is out, and all washed ready for a fresh coat of paint ( and no i dont class that as a rebuild ha ha ha). I had a friend over to help, he brought his pressure washer , so by the end of the day the Hull is clean and ready for a rub down. Things keep move on !

shaun · #14 28-12-11, 22:36

a few more photos

shaun · #15 28-12-11, 22:38

And a couple more

kevin powles · #16 28-12-11, 23:29

Hi Shaun, Any chance on having that rear storage box you have removed here for a couple of weeks to study and fabricate.

Kevin.

shaun · #17 31-12-11, 11:22

The "A" team turned up to help yesterday in the form of 2 mates Steve and Josh Garrett, Steves a serving REME WO1 and Josh joined the Army 2 months ago . so between the 3 of us we had REME servicemen of bottm of the tree - top of the tree - past the tree ! But this did all help in getting the engine and transmission back in the hull after a freshen up with some fresh paint between the engine rails.

This is all a bit familier from a few months back with the MK1 ! and i think i will be doing this all again on another carrier in a month or so !! But thats another story !

RichardT10829 · #18 31-12-11, 13:49

Shaun...aka "Mr rapid turn around" mind i admire the size of your gonad's putting the strop around the two bolts in the bell housing mate

I wish i lived down there...could have got mine finished in a matter of weeks rather than the months and months i have ahead of me hahahaha

Alex Blair (RIP) · #19 31-12-11, 14:18

Quote:

Originally Posted by shaun

The "A" team turned up to help yesterday in the form of 2 mates Steve and Josh Garrett, Steves a serving REME WO1 and Josh joined the Army 2 months ago . so between the 3 of us we had REME servicemen of bottm of the tree - top of the tree - past the tree ! But this did all help in getting the engine and transmission back in the hull after a freshen up with some fresh paint between the engine rails.

This is all a bit familier from a few months back with the MK1 ! and i think i will be doing this all again on another carrier in a month or so !! But thats another story !

It looks to me that who ever sprayed that engine didn't plug the plug holes and sprayed paint right into the engine..
I'm sure that the plugs went in after the spray job and the engine..has now hardened spray paint in on top of the pistons..
I'm sure that that will break down and be exhausted but would bet $$$$$$$$ that the oil would be effected by the burnt and lingering paint residue and will happen as soon as the gas mixture hits the paint..
..
Lot easier to do it right the first time that do it over..
Just my observations but I may be wrong..
I have been wrong once before.
happy new year.

shaun · #20 31-12-11, 14:23

Richie its no good sitting arround on internet forums all day !!! ha ha ha you have to get out in that nice new workshop of yours and crack on ( have you turned the heating on in the workshop yet ?) I have to many projects to do to hang about.

I have always lifted on the bell housing bolts, just make sure they are wound in a good way. It looks a bit on the dodgy side but it save disturbing the head nuts.

i better go get on i need this out in 3 weeks Happy new year.

shaun · #21 31-12-11, 14:26

Alex - i will let you know the out come !

Quote:

Originally Posted by Alex Blair

It looks to me that who ever sprayed that engine didn't plug the plug holes and sprayed paint right into the engine..
I'm sure that the plugs went in after the spray job and the engine..has now hardened spray paint in on top of the pistons..
I'm sure that that will break down and be exhausted but would bet $$$$$$$$ that the oil would be effected by the burnt and lingering paint residue and will happen as soon as the gas mixture hits the paint..
..
Lot easier to do it right the first time that do it over..
Just my observations but I may be wrong..
I have been wrong once before.
happy new year.

Ron Pier · #22 31-12-11, 14:41

I might well have plugged the plug holes to save paint getting in the threads. But I would think that the tiny amount of paint that would end up on the valve heads would be blown out the exhaust in a very few revolutions. Ron

RichardT10829 · #23 31-12-11, 17:07

likewise if it was a top fuel dragster running 14:1 CR i would be a teeny tiny bit worried.... carrier engine....not so much.

Shaun i am at work matey...got 10 days off coming up, looking to get the carrier rivetted in that time.

fingers crossed.

shaun · #24 31-12-11, 18:15

If i was closer i would be there drinking your tea Richie ! just keep your crossed fingers out of the way of the riveting guns ! I think its time we had an up date from you though !!

eddy8men · #25 31-12-11, 20:05

good to see the reme in action, no wonder it went so well.
3 is always a good number for a pack lift, 1 brewing up, 1 supervising and 1 to do the work

all the best for the new year

rick

Alex Blair (RIP) · #26 31-12-11, 21:09

Quote:

Originally Posted by shaun

Alex - i will let you know the out come !

Shaun..
I have been following your rebuild and admire your work..
I have rebuilt and painted many an old flat head and found that a ball of old masking tape made an ideal plug for the plug holes..'
I just thought that ,being so fussy with he rest of your work you would have plugged the holes before painting..
Probably will get away with it..They are pretty forgiving..but I did loose one with old oil,contaminated with condensation..so it doesn't take much.
Happy new Year and keep up the great pictures..
very interesting.
Alex

shaun · #27 10-01-12, 00:05

The job is moving on well, just boring at the moment. IE clean the part , prep the part for painting, paint the part , fit the part - i could post some photos of paint drying but i thought i would leave them for another day. But work is still going on.

shaun · #28 10-01-12, 00:11

Having thought about my last most - just for Richie here is a photo of some green paint drying !

RichardT10829 · #29 10-01-12, 00:46

Arghhhh my eyes my precious eyes...hehehehe

horsa · #30 10-01-12, 01:53

I keep checking the photo you posted and it hasn't changed...is it dry yet

Looking good.