Emergency Whatdown?

Today's blog I found the emergency shutdown solenoid on the bus not only disconnected but...

 If anyone understood the system you would know that this picture can't happen unless you have a very fast camera.

 The shaft on the flapper door to trip in an emergency by the shutdown solenoid is frozen in the open position. Something else to fix.

4-29-2011 update

During the day today I beat, cut, lubed, heated and destroyed the shaft in the unit but it is now out. 

I need the shaft and the spring for the plate

The good pieces are in the baggie and the plate could be re used

The spring was toast before I ever started

The shaft is mild steel and the housing is aluminium,

 dissimilar metal corrosion had a real good grip on the two of them 

The plate was held to the shaft with two roll pins.  How anyone ever intended to remove them for any type of service is beyond me. I found it necessary to tap them until they bound with the outer case and then die grind off the pins to get enough room to tap them the rest of the way out.

Another person on the busconversion forum said he had a complete unit I will see what he wants for it.

Brian's air box on delivery was completely different.  So the process of rebuild was started.

The picture below is after I reamed out the housing to put in two bronze bushings on a new shaft and re pinned the components on the shaft.

A lot of time was lost looking for a new or good used spring like the original to pre-load the door in side the box.  Eventually new springs were sourced from McMaster Carr and installed.

All parts were re secured with new roll pins and the interior roll pins were arched in place to keep any possibility of ingestion to a minimum.

All the components are re pinned in place now I need to actuate the Air box.

The old dogs and brackets are trashed and do not have a solid connection.

After hours of looking for something to replace them with at all the home improvement stores the solution was paper templates and flat stock sheet metal. Now two new brackets and a spring allow the Air box  to operate as needed.

One Bracket to release the catch on the shaft and trip the air box.

And a second to put tension on the return spring so the Air box resets when the shaft is turned.

Now the completed release and reset portion of the Air box.