19/11/2023

Work on the electrics has continued this week with examination and the start of refurbishing the control box.  I have worked out the connection system for external wiring (lights, horn etc) and how the switches on the top of the unit are connected and identified and cleaned all the terminal points for the external circuits and am in the process of replacing all the steel 2BA terminal nuts with brass. The p-clips for the griplock conduit that runs fromt he cab to the boot arrived on Wednesday and have been installed so the conduit is now fastened back properly to the chassis.  As a consequence I have now trimmed the end of the multicore in the boot, soldered on the ring tags and attached to the terminal strip in the lid of the terminal box in the boot, including a link for an additional -ve return.  After that I returned to work on the control box and repaired the broken hinge by making a new one out of 1/8″ galvanised steel plate, an intricate shape that required careful design.  The whole alloy base of the control box needed to be removed in order to gain access to the hinge pins which were very stubborn to remove and required a lot of careful heating and attention from a small hammer and punches.  I also needed to remove the base of the old hinge which I did succesfully with the angle grinder then dressed it flat with a file.  The new hinge is attached with 2BA countersunk screws threaded into the hinge base and to which I will add locknuts in the final assembly.   The hinge part has been drilled for its pin and just requires final shaping before the base of the control box can be reassembled.  I turned a new pin to replace the old one which was unusuable after removal, this just requires final finishing, parting off and drilling for a split pin.  The pin from the other side has been cleaned up and just needs drilling for a split pin.