1939 Leyland TD5 [1635 DD]

Norman Julian 24 Oct
Hello fellow humans.
I'm back doing some work on one of my projects although only small.
Because of some stupidity I did some time ago I did some damage to a double hernia operation and 2 weeks ago I went under the knife
to repair that so for the moment I have to take it easy, hense the reason for not many updates.
Anyway, as you can see I'm on the verge of finishing off this very time consuming radiator.
54 tubes all up and very slow to bring back to what they used to look like when new.
I was wondering how I was going to deal with 2 that are bigger than the standard size ones.
I started sitting there doing the same things I did with the others and realised that I'm going to have an issue getting them back in with the others.
They are all densely packed anyway so trying to get them in somewhere was going to have problems.
Even on the ends.
I think that is why some of the tubes had collapsed loops.
I have decided to just use straight copper tube to replace them.
They will go in the middle row where they cannot be seen.
I have also put a picture of the bottom section of the radiator shroud.
It is missing a section for the right hand side which resembles the left.
None can be sourced so I will get another one cast.

Terry Davis
Hi Norman so sorry to hear about your operation l sincerely hope that you have a 100% recovery;
take & dont over do it ; best regards. 😁👍✌
Norman Julian
Terry Davis thanks buddy!
Julian Portelli
Hope your better now
Norman Julian
Julian Portelli getting there thanks!
Robert Stevenson
Take it easy on yourself Norman.
Would that be the foofoo valve you busted that I have heard people talk about?

Norman Julian 24 Oct
Just thought I would show a little sample of what has to be done.
Before and after shots.
I use a small screwdriver that goes into the loop and pulls it up straight.
Then each row is spaced relatively even.
I have to have regular breaks because this job will send you Cuckoo after a while.
The other 2 radiators I could manage to do maybe just over 2 a day.
This radiator is 1 if I'm lucky.

Norman Julian
These may look like individual rows of coils but they actually spiral from one end of the tube to the other.
Bryce Pender
I wonder if something like this spiral vege cutter would work?
Norman Julian
Bryce Pender no mate.
Unfortunately my way is the only way!
Bryce Pender
I am sure I have seen radiator shops with combs to straighten them
Norman Julian
Bryce Pender they are crushed, twisted and bent out of shape.
Don't think there is an easy way out!
Robert Stevenson
Are the coils fixed to the tube along the length, or just at the ends?
Would have loved to see how the were originally made.
Norman Julian
Robert Stevenson very complex indeed

Norman Julian 26th Oct
I find just about any technology facinating.
This is no exception.
It appears that these loops are formed out of one continuous length of wire.
It is all held into position by a thicker piece of wire which is spiraled around and soldered onto the brass tube.
Here in this first picture you can see the loop being pulled and stretched out.
Just where the first loop starts you can see a thicker wire coming through at the base.
You can also see a band of solder just to the right of that loop.
How back in the early thirties or for that matter anytime this was done is very facinating.

Fred Holland
😏interesting Norm something you could do without.
Norman Julian
Robert Stevenson this will hopefully answer your question
Robert Stevenson
Norman Julian close enough.
Would have been a fun job building it originally.
Robert Stevenson
The thicker wire is continuous as well?
Norman Julian
Robert Stevenson the thicker wire spirals around the brass tube from one end to the other spaced evenly with the thinner
wire from a continuous length forming a loop being held in position by that thicker wire.
It is all held in position by a continuous bead of solder on the brass tube.
Robert Stevenson
Norman Julian got it.
Would have been a nice little machine to make that all.
Gregor Neil Robertson
And there was a far more vibrant culture of innovative engineering in those days.
And before WW2 there was a huge available workforce of men with the skills and aptitude -
and the patience not often found now, to do laborious repetitive work.