Post Christmas fettle challenge

Discussion in 'Fettling Forum' started by MozzoSA, Jan 25, 2020.

  1. MozzoSA

    MozzoSA Australia Subscriber

    Offline
    Joined:
    Oct 6, 2019
    Messages:
    59
    Location:
    South Australia
    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 IMG_20200125_114202.jpg IMG_20200125_114212.jpg IMG_20200125_130810.jpg IMG_20200125_130822.jpg
     
  2. phaedrus42

    phaedrus42 Subscriber

    Offline
    Joined:
    Jun 14, 2014
    Messages:
    1,936
    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.
     
  3. MozzoSA

    MozzoSA Australia Subscriber

    Offline
    Joined:
    Oct 6, 2019
    Messages:
    59
    Location:
    South Australia
    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.
     
  4. JEFF JOHNSON

    JEFF JOHNSON United Kingdom Subscriber

    Offline
    Joined:
    Nov 28, 2010
    Messages:
    9,469
    Location:
    Shetland Islands UK..
    Happy fettling!:thumbup:
     
  5. Tony Press

    Tony Press Australia Subscriber

    Online
    Joined:
    Aug 28, 2012
    Messages:
    5,759
    Location:
    Stinkpot Bay, Howden, Tasmania, Australia
    @MozzoSA

    A Tilley burner will fit it. I might have one in the shed.


    Cheers

    Tony
     
  6. Thomas

    Thomas Subscriber

    Offline
    Joined:
    Jun 24, 2017
    Messages:
    137
    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.
     
  7. MozzoSA

    MozzoSA Australia Subscriber

    Offline
    Joined:
    Oct 6, 2019
    Messages:
    59
    Location:
    South Australia
    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.
     

    Attached Files:

  8. MozzoSA

    MozzoSA Australia Subscriber

    Offline
    Joined:
    Oct 6, 2019
    Messages:
    59
    Location:
    South Australia
    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.
    IMG_20200217_202842.jpg
     
  9. Pancholoco1911 United States

    Offline
    Joined:
    Nov 26, 2019
    Messages:
    68
    Location:
    USA
    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

    6146444275_a56a7c2b85_b.jpg 6153957327_4d20081559_z.jpg
     
  10. Tony Press

    Tony Press Australia Subscriber

    Online
    Joined:
    Aug 28, 2012
    Messages:
    5,759
    Location:
    Stinkpot Bay, Howden, Tasmania, Australia
    The old Tilley and Kayen burners are a pretty complex piece of engineering.

    Kayen/Tilley
    26AEF97D-19CF-4571-9CA1-274E3E2298E9.jpeg

    Or

    "modern" Tilley with pressed brass parts and lighter materials.
    1F7CE1FC-67A4-446F-AA2A-874A681B2D9D.jpeg


    Cheers

    Tony

    Edited for more detail.

    @MozzoSA
     
    Last edited: Feb 20, 2020
  11. MozzoSA

    MozzoSA Australia Subscriber

    Offline
    Joined:
    Oct 6, 2019
    Messages:
    59
    Location:
    South Australia
    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.
     
  12. Tony Press

    Tony Press Australia Subscriber

    Online
    Joined:
    Aug 28, 2012
    Messages:
    5,759
    Location:
    Stinkpot Bay, Howden, Tasmania, Australia
    The complicated bits aren’t shown in the photos - all air the holes etc.

    Tony
     
  13. Graham P

    Graham P Australia Subscriber

    Online
    Joined:
    Mar 3, 2012
    Messages:
    843
    Location:
    Albury area NSW AUstralia
    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 .
     
  14. MozzoSA

    MozzoSA Australia Subscriber

    Offline
    Joined:
    Oct 6, 2019
    Messages:
    59
    Location:
    South Australia
    Good point Graham. Will do
     
  15. MozzoSA

    MozzoSA Australia Subscriber

    Offline
    Joined:
    Oct 6, 2019
    Messages:
    59
    Location:
    South Australia
    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?
    IMG_20200227_193542.jpg
     
  16. Tony Press

    Tony Press Australia Subscriber

    Online
    Joined:
    Aug 28, 2012
    Messages:
    5,759
    Location:
    Stinkpot Bay, Howden, Tasmania, Australia
    I’ll double check tomorrow morning.

    Cheers

    Tony
     
  17. Tony Press

    Tony Press Australia Subscriber

    Online
    Joined:
    Aug 28, 2012
    Messages:
    5,759
    Location:
    Stinkpot Bay, Howden, Tasmania, Australia
    @MozzoSA

    Tilley has the air tube pressed in place:

    9166B916-6B95-4156-A88C-48FD3769E219.jpeg

    Kayen has it silbrazed:

    4399CC74-8960-45F7-ACF2-7EB4A5EA082F.jpeg

    Cheers

    Tony
     
  18. MozzoSA

    MozzoSA Australia Subscriber

    Offline
    Joined:
    Oct 6, 2019
    Messages:
    59
    Location:
    South Australia
    Thanks Tony
    I don't trust myself to press it. Will silver solder it. I've already machined up an airtube from solid brass.
     
  19. MozzoSA

    MozzoSA Australia Subscriber

    Offline
    Joined:
    Oct 6, 2019
    Messages:
    59
    Location:
    South Australia
    That worked!
    IMG_20200229_141103.jpg
     
  20. Tony Press

    Tony Press Australia Subscriber

    Online
    Joined:
    Aug 28, 2012
    Messages:
    5,759
    Location:
    Stinkpot Bay, Howden, Tasmania, Australia
    Excellent!

    Cheers

    Tony
     
  21. MozzoSA

    MozzoSA Australia Subscriber

    Offline
    Joined:
    Oct 6, 2019
    Messages:
    59
    Location:
    South Australia
    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.
     
  22. podbros

    podbros United Kingdom Subscriber

    Offline
    Joined:
    Dec 27, 2015
    Messages:
    862
    Location:
    Wirral
  23. MozzoSA

    MozzoSA Australia Subscriber

    Offline
    Joined:
    Oct 6, 2019
    Messages:
    59
    Location:
    South Australia
    IMG_20200318_175910.jpg Progress shot.. still needs finishing polish and protection. Admittedly the Kayen reflector makes it a Frankie.
     
  24. Tony Press

    Tony Press Australia Subscriber

    Online
    Joined:
    Aug 28, 2012
    Messages:
    5,759
    Location:
    Stinkpot Bay, Howden, Tasmania, Australia
    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
     
  25. podbros

    podbros United Kingdom Subscriber

    Offline
    Joined:
    Dec 27, 2015
    Messages:
    862
    Location:
    Wirral
    That looks fab!:thumbup:.. I bet you're really pleased?

    Well done Mozzo! :)
     
  26. AussiePete

    AussiePete Australia Subscriber

    Offline
    Joined:
    Nov 21, 2015
    Messages:
    2,441
    Location:
    Toowoomba Australia
    That looks awesome, well done @MozzoSA
    Cheers
    Pete
     
  27. MozzoSA

    MozzoSA Australia Subscriber

    Offline
    Joined:
    Oct 6, 2019
    Messages:
    59
    Location:
    South Australia
    IMG_20200326_160527.jpg IMG_20200326_160535.jpg

    Pretty much completed now. Looks too nice to light it.
     
  28. Tony Press

    Tony Press Australia Subscriber

    Online
    Joined:
    Aug 28, 2012
    Messages:
    5,759
    Location:
    Stinkpot Bay, Howden, Tasmania, Australia
    Excellent! :thumbup:


    Tony
     
  29. ROBBO55

    ROBBO55 Subscriber

    Offline
    Joined:
    Oct 21, 2014
    Messages:
    1,752
    Location:
    Somersby, New South Wales, Australia
    Looks good :thumbup:
     
  30. Alex74

    Alex74 United Kingdom Subscriber

    Offline
    Joined:
    Oct 13, 2019
    Messages:
    229
    Location:
    Faringdon, Oxon
    That’s one of the best fettle jobs I’ve seen on here. Like new. Really well done!
     

Share This Page