So now that I have the fettling bug I've decided to have a go at a bigger challenge. Manager to acquire this Kayen heater. Fount really dented and missing the whole burner. I'm planing to give the fount the ice treatment as a start. Moz
That is a pretty big dent. The volume of water expands by about 9% when it freezes. It may take more than one ice treatment to get the dent out. If you go the freezing route, consider first freezing a 1" or more layer of water in the bottom of the fount. This will protect the bottom lead seam of the fount. Another option is the heat method: Fill the fount with chilled water to a little below the dent. Use the pump to pressurise the fount to moderate pressure. Then play a butane torch around the edge of the dent in a spiral motion as the dent comes out. Not too much heat, and the water must never boil. The process should only take a few minutes.
Thanks for the tips. I know it will be difficult to repair the dints but I have time on my side. Finding a burner will be a challenge I expect. Might have to make one from scratch I expect.
If you made an adapter to connect the font to a pressure washer you could pop those dents out. I've seen guys do it with dented two stroke expansion chambers.
So the ice wasn't going to get these dents out. I gave up on that,fired up the oxy torch and took the bottom out. That made it easier to peen it out closer to the original shape. Then I spun it in the lathe and kind of rolled the bumps down from the outside. Next I will place it in an external jig and do some fau metal spinning from the inside to get the shape back that I stuffed up with the outside roller.
Can someone help me with some dimension sketches of how the burner goes together though? I bought these parts via bay of evil. But I don't have any idea the structure or dimensions of the rest.
Found some pictures over the web and look like you still need some parts. Also get a lamp gallery and use it as lamp/lantern
The old Tilley and Kayen burners are a pretty complex piece of engineering. Kayen/Tilley Or "modern" Tilley with pressed brass parts and lighter materials. Cheers Tony Edited for more detail. @MozzoSA
Thanks guys. I can see the old design could be fabricated on a lathe but I'd have trouble with the large threads. I will think on it a while. Maybe I will surprise us all.
Looks like you have given it a work over,(it may pay to anneal it as you go.) I have seen a couple of these with random stress cracking .
So in the end I bough a second heater, the plan is to make one from two. This one a Tilley. The reflector is badly damaged but the fount is good and it has a burner in reasonable condition. I just need to make and fit a new air tube to the burner. @Tony Press how is the air tube secured to the outer shell on yours?
Thanks Tony I don't trust myself to press it. Will silver solder it. I've already machined up an airtube from solid brass.
Next task is to get the reflector looking like new. Of course it's going to tarnish again over time. To paint it or not.. I wonder how the clear 2 pack spray paint will handle the radiant heat.
Progress shot.. still needs finishing polish and protection. Admittedly the Kayen reflector makes it a Frankie.
I think I've lost track of which bits are which, but Nettlefold and Kopsen both mixed Tilley parts with their own gear during the trade restrictions, at least until the Tilley stock ran out, and the service shops used whatever was to hand... Cheers Tony
