4 Wheel Braked Truck
4 Wheel Braked Truck |
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Once again the small 3mm hole to bolt the brake shoe
on to the brake hanger has to be drilled. Mark a point on
the brake shoe where the red circle is in the diagram to
the left. Then inset the brake hanger in to the back of
the brake shoe, lining up the hump in the hanger with the
centre of the shoe. Clamp the shoe on to the hanger and drill straight through both the shoe and hanger. Before removing the clamp insert a 3mm x 16mm bolt through. The brakes are handed so be sure to get two matching pairs. Looking down on the top of the brake shoe you will see the braking face is angled. The shortest side goes against the flange. The bolt goes in from the opposite side leaving the nut hidden on the inside. |
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The brake hangers are then held off the chassis via 30mm x 5mm bolts. Push the bolt through from the outside of the chassis and then run on three 5mm bolts. Lock these up tight so they cannot move. Slide the brake hanger onto the 5mm bolt before following with a nyloc nut. Run the nyloc nut up tight against the brake hanger then back turn so the hanger is free to move.
Repeat this for all four brakes.
Instert the brake cross pieces "A" in to the brake hangers. Rotate the cross bar so the lump in the centre faces the centre of the truck. Now loosely bolt the two long draw bars "B" on to the cross bars.
The pictures below are probably easier to follow than trying to describe in text.
The drop hanger part "D" has to be bent to one side as illustrated below.
Fitting the brake lever, crank and shafting collar
Supplied are three components in 8mm steel. All of these need fixing to the main spindle. Both the crank and handle take quite a load so. We tend to weld these on for a final solution but other methods are perfectly acceptable. One method is to drill and tap all the components for a 4mm grub screw (red arrow).
Fit the two oilte bearings to the chassis and slide the spindle in from one side (left side for brake lever on left, right side for lever on right). Slide on the shafting collar, then the crank and finally the brake lever. Move the crank to the centre and the collar and handle to the ends. As you will see the brake lever rests down on one of the bolts fom the axle box guides.
To centre the brake gear, loosen the top bolt "C" and apply the brakes. With them still applied tighten bolt "C". This will then have centred the brakes.When you know it all works drill straight through the handle/crank and the spindle and fit a split pin (green line on component diagram).
Running The Truck
Beware - apply brakes carefully as it easy to tip yourself over with the sudden stop.
OLD BEARING HOLDERS
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Assembly of the bearing
holders The bearing holders are made up from a sandwich of 4 layers of steel
The laser cutting of holes in steel is limited in size as too small a hole tends to block with clinker from the cutting process. This means that the 3mm holes through the 5mm centre holder have to be drilled. To do this use the 3mm cover plate as a template for the four holes. The whole assembly is then held together with four 16mm x 3mm bolts and nuts. Place the chassis on its back. Before proceeding, check to see if these assmebled axle boxes fit in the slots on the chassis. File down accordingly until they move freely in the slots. Clean out using a file the inside edges of the axle box guides and again check to see if the axle boxes slide freely in them. Please an axle box on each bearing at the end of the axle and lower in to the chassis. The axle should now move freely up and down. Fit the 3mm spring support plate through the axle guide and fit into place over the axle box leaving the 3mm spring support plate just on the two spring lumps. Now lift the axle box up passed the axle guide and poke the two springs in. Now push the axle down and all parts should slot in to place. - Will take a picture next time I am assembling one. Its a lot easier doing than describing. |
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