Now, for the Rear Axle ......

As many would be aware, our old trucks and buses can be very slow by today's standards, and this was definitely the case for Albert. The decision was made to increase Albert's road speed to help keep up with today's speed; nobody wants to be stuck behind an old bus, right? Andy is currently working on the installation of a higher ratio differential which, when combined with the previously fitted 2 speed transfer box, will allow a top road speed of 50mph (80kph)...”vital for safe driving on European motorways and trans- Australian highways!” explained Andy.
With a higher ratio it means that even though the engine speed may remain the same, the rear wheels turn faster, so the bus goes faster.

The 2 speed transfer box (silver case, looking to the rear of the bus. When its higher speed is engaged, the wheels turn 30% faster than normal. So instead of doing 40 mph, the bus (theoretically, and if you are brave enough) can do 53 mph. (83 kph!)

STOP PRESS!

On close examination the rear axle was found to be in quite good condition.

Andy, head down tail up, cleans off the diff. after taking off the top cover.

And the greatest surprise of all was that it was already the higher ratio: how could this be?? According to all the known wisdom, Sydney Albions were limited to 32 mph by having a 6/24 axle ratio. (don't worry about remembering that). Albert has a 5/27 axle: photographic evidence:

Can you see it? At centre LHS, stamped into the casing is 5/27 (click on the photo)
Further proof, as if the stamp on the case could be wrong! There it is, stamped into the pinion itself: 5/27.

The innards of the axle: the worm drive wheel and inside it, the differential.

The bronze wheel is in lovely condition despite thousands of miles on rough terrain, and the passage of 40 years since it was last looked at. A caliper is used to check the wear on the teeth of the bronze pinion: only 0.26 mm. wear after 50 - 60 years! A brand new pinion was measured and found to be 8 mm. at his point.

As an aside: this question of the axle and its ratio must have generated about 20 emails: there was much discussion on just how a bus supposed to be capable of 32.5 mph maximum governed speed, could now apparently do 40 mph!

With this work on engine and driveline underway, work also began on the new floor to the top deck, complete with fresh wall panelling and a splash of brightly coloured paint.

For more information on the Crew Register, visit the website: www.highroadforoz.info

You can be involved in this great adventure.

The Engine; Albion 6-cylinder diesel

In order for Albert to be mobile again, the engine was removed for overhaul and after re-installation, No. 2004 was to be independently mobile for the first time in 30 years.

The engine comes out for overhaul
The only Albion engine to have been from Britain to Australia five times. Paul Adams, Scottish owner of restored Sydney Albion no. 1877, watches
In every Albion diesel, the engine side plates and their bolts are rusted from the cooling water. Andy gets into some skilled fitting work drilling out the bolts and threading them for new bolts.
Friends, and Albion experts, John Rentoul and Derek remove pistons and connecting rods.
Cleaned, parts laid out, Derek, John and Davie make it look easy.
In the finest traditions of Scottish engineering: Peter Burt, John Rentoul and Derek Ferguson machine engine valves to a perfect finish
Reassembled: the engine is started for the first time in perhaps 20 years, in a cloud of smoke (and deafening noise?) from the exhaust . Note the makeshift oil gauge, battery leads to the starter, and a pipe at right to stop the engine itself spinning around! John Rentoul and Cliff Martin feel quiet pride.Up top, the valve gear clatters in a satisfying sort of way. John's hand is on the exhaust manifold so it can't have been running long!
The rebuilt engine and gearbox at rear is readied for installation. In a double decker you need lifting gear which can reach under the top deck overhang. The piece of orange tube along the bottom casing is where the dynamo should be: more of that later.

This mobility then allowed the rear end overhaul to begin, including a back platform, stairs, rear wheel arches and the rear chassis.

Independently mobile: the engine is back in, running, a lot of new bodywork has been done, but that roof, my dear!!.... Well it had to be made like that to fit under bridges in India, and is to be remade with Andy's skills having matured over the last 35 years!The engine refitted, running, and a temporary radiator from an Albion truck in place. Andy couldn't wait for the original to be finished off in Glasgow before he could take Albert for a run, however brief.

Paul Adams and Derk Ferguson in Glasgow this time, work on Albert's original bus radiator: different in some ways to the truck ones. At left to confuse the issue is another Albion, a truck, under restoration.
The original radiator, polished, and with new gaskets and rubbers throughout, fitted. All the Sydney Albions had a 'Venturer' badge once, but they were souvenired or just left off by staff, and to find one now has been lucky.

The dynamo presented a challenge as the original had been taken sometime during the 2002-2009 era. An original Chullora (NSW) dynamo was donated by friends of Albert, which resolved the problem. Shipping from Australia was a challenge but Roy Bartlett of Freightbiz, himself a Pom, gave us a pretty good deal on the 5okg. crate. Off it went by air, then, just when everything seemed to be going well, the dynamo was ‘hijacked’ by a handling agent wielding ‘red tape’ and imposing amazing import fees at Edinburgh Airport! A nice little earner for an unscrupulous Customs man, referring 'clients' (i.e. victims) to his mate. A direct appeal to a commonsense UK customs official finally saved the day. An original CAV 24 volt dynamo (generator) in amazing condition for its 50-odd years, gets a cleanup at Turramurra Works.

A thing of beauty (in the eyes of some beholders) is a joy forever: the rotating armature from the dynamo polished and ready to be assembled.