HOME
Peoples Projects
Pete's Project.
To install a 10/1 coupled to a 7.5Kw ST Generator in the shed. Just enough room. I did this by myself with no help from anybody except the welding on the chassis. If the genset needs to be removed the whole chassis can be jacked up and moved in one go.
During this project several combinations have been tried, tested, worked or failed but perseverance has been the key to it's success although it's not finished yet.
Old air cooled Chinese genset removed. Floor cut, old concrete and steel dug out, great fun!!
Hole 48x24x18 inches. Filled with 0.8Tons of concrete and steel for new chassis pictured sitting on one inch TICO PAD held down by 6 inch rawl bolts.
January 31st 2007. I spy a 10/1. Tea break over and it's into the shed, now with a new hinged left hand side.
Some good wood for packing and a piece of steel plate level with chassis top. Sling left on as a safety.
Nearly there A snug fit
Then it started raining, rather good timing I thought. ST generator attached to chassis, no drive belt yet.
Upper and lower slide plates. Crossmember drilled to take adjusting threaded rod which goes into captive welded nuts on lower plate allowing tensioning and aligning of the drive belt.
First video 4th February 2007 3.15pm Listerclone started for first time. Not a brilliant video but shows how the engine is well balanced. Temporary water pipes fitted so I could put some water in the engine. Full pre run inspection check carried out as described in the Lister manual. It started on the third attempt and came up to speed nice and smoothly. Second video 11th February 2007. Three silencers fitted but exhaust heat exchanger had 3 very tiny leaks and was not effective at raising the temperature at all ,a different one must be designed to suit. COV removed and glowplug fitted, easy cold weather starts now. Pepperpot silencer removed ,replaced with a heat exchanger. (Proved to be inefficient) 18th February 2007 New drive belt fitted but is now a bit harder to start. A quick test of 10 minutes allowed me to run a 3Kw fan heater, the lights and it started my heat pump with no problem. An additional load of a 3Kw immersion heater made the voltage drop and the engine smoke a lot. Proposed starter motor which did not work rated at 1 Hp 230vac but swivel mount did. March 2007. After several attempts to find and fabricate a 12 volt starter was finally fitted. Engine still needs turning by hand but now only a little effort is required to start it. New insulated pipes were laid to the house to carry the hot coolant plus electric cable. A partition and veg oil tank were installed along with outside radiator. Volvo 240 radiator with Fiat electric fan. Engine exhaust comes out of shed behind radiator. Two lower valves are for connection to house. Standard domestic central heating pump used in coolant circuit. April and May 2007.Due to work commitments progress has been slowed down . Sound proofing tiles added which meant a complete strip out. Helmhotz resonator experiment to reduce induction noise worked after some experimentation with different lengths of pipe. Purpose built exhaust heat exchanger finally arrived after the older one sprung a leak. 24vdc 55 amp alternator added to charge batteries up. Setting exhaust heat exchanger in place but disaster struck with the heated veg oil tank fracturing on an internal weld. Final position of heat exchanger with a Helmotz resonator, Shogun and Landrover Discovery air filters in position in the foreground. This solved the induction noise. Twin dustbin (garbage can) silencers filled with rubble and gravel solved the exhaust noise to a certain extent. A more suitable solution will be an exhaust pit underground. This has yet to be designed but will be based on an old idea that was used in factories many years ago. After tests it was found to be noisier than at first hoped but did allow condensation to drip into the pit. A temporary setup with a pipe welded onto a piece of Volvo exhaust was used. After this it was decided to just have a pipe to let any condensation drip into the pit and run the exhaust down the garden and up a tree. Problem is that annual bedding plants are in the way at the moment so a permanent underground plastic pipe will have to be put in when they have finished. The upright section temporarily up the tree works well with nearly all the noise removed. These 6 photos below were added at end of August 2007. On the engine a few things have been fitted but nothing piped up yet. On the injection pump is a 12vdc change over solenoid. On the injection pipe is an aluminium block to take hot water for heating the veg oil. On the rear of the engine is an inline heat exchanger for heating the veg oil before it enters the injection pump. 24vdc starter finally wired up complete with starter switch and twin solenoids. Governor control spring altered for ease of use. New veg oil tank made from standard central heating header tank. Pipe work is a heated fuel pickup. A maze of pipes !!. Veg oil tank is on right, above and to left is fuel pump, prefilter and main heated filter. The fuel travels from there through the copper heat exchanger into a TEE junction. To the left it goes to a 12vdc solenoid switch over valve, to the right it goes through a temperature sensor and back to the tank. This is a continuous loop running all the time therefore putting no excess pressure on the main fuel injection pump. The main water outlet from the engine is TEED several times to the veg tank, the main veg oil filter, the copper heat exchanger and the injection line heater. June and July 2007.Again not much accomplished due to work commitments. Automatic float vents installed with temperature sensor for pump control. They were installed to remove excess air. Beginning to get a bit tidier now with partition in place but the batteries arrived so space had to be made. The 1500 pure sine wave inverter is for driving my heat pump and computer. 3 Kw pure sine wave inverter to supply house at night. New belts fitted to ST Generator and 24 vdc alternator. A smaller pulley was also fitted to the generator as well. This enables the engine to run at a lower speed but driving the 24vdc alternator considerably faster. January 2008 Click to go to 2008
First video 4th February 2007 3.15pm Listerclone started for first time. Not a brilliant video but shows how the engine is well balanced. Temporary water pipes fitted so I could put some water in the engine. Full pre run inspection check carried out as described in the Lister manual. It started on the third attempt and came up to speed nice and smoothly.
Second video 11th February 2007. Three silencers fitted but exhaust heat exchanger had 3 very tiny leaks and was not effective at raising the temperature at all ,a different one must be designed to suit.
COV removed and glowplug fitted, easy cold weather starts now. Pepperpot silencer removed ,replaced with a heat exchanger. (Proved to be inefficient)
18th February 2007 New drive belt fitted but is now a bit harder to start. A quick test of 10 minutes allowed me to run a 3Kw fan heater, the lights and it started my heat pump with no problem. An additional load of a 3Kw immersion heater made the voltage drop and the engine smoke a lot.
Proposed starter motor which did not work rated at 1 Hp 230vac but swivel mount did.
March 2007. After several attempts to find and fabricate a 12 volt starter was finally fitted. Engine still needs turning by hand but now only a little effort is required to start it.
New insulated pipes were laid to the house to carry the hot coolant plus electric cable.
A partition and veg oil tank were installed along with outside radiator.
Volvo 240 radiator with Fiat electric fan. Engine exhaust comes out of shed behind radiator. Two lower valves are for connection to house. Standard domestic central heating pump used in coolant circuit.
April and May 2007.Due to work commitments progress has been slowed down .
Sound proofing tiles added which meant a complete strip out. Helmhotz resonator experiment to reduce induction noise worked after some experimentation with different lengths of pipe.
Purpose built exhaust heat exchanger finally arrived after the older one sprung a leak. 24vdc 55 amp alternator added to charge batteries up.
Setting exhaust heat exchanger in place but disaster struck with the heated veg oil tank fracturing on an internal weld. Final position of heat exchanger with a Helmotz resonator, Shogun and Landrover Discovery air filters in position in the foreground. This solved the induction noise.
Twin dustbin (garbage can) silencers filled with rubble and gravel solved the exhaust noise to a certain extent. A more suitable solution will be an exhaust pit underground. This has yet to be designed but will be based on an old idea that was used in factories many years ago. After tests it was found to be noisier than at first hoped but did allow condensation to drip into the pit. A temporary setup with a pipe welded onto a piece of Volvo exhaust was used. After this it was decided to just have a pipe to let any condensation drip into the pit and run the exhaust down the garden and up a tree. Problem is that annual bedding plants are in the way at the moment so a permanent underground plastic pipe will have to be put in when they have finished. The upright section temporarily up the tree works well with nearly all the noise removed.
These 6 photos below were added at end of August 2007.
On the engine a few things have been fitted but nothing piped up yet. On the injection pump is a 12vdc change over solenoid. On the injection pipe is an aluminium block to take hot water for heating the veg oil. On the rear of the engine is an inline heat exchanger for heating the veg oil before it enters the injection pump.
24vdc starter finally wired up complete with starter switch and twin solenoids. Governor control spring altered for ease of use.
New veg oil tank made from standard central heating header tank. Pipe work is a heated fuel pickup.
A maze of pipes !!. Veg oil tank is on right, above and to left is fuel pump, prefilter and main heated filter. The fuel travels from there through the copper heat exchanger into a TEE junction. To the left it goes to a 12vdc solenoid switch over valve, to the right it goes through a temperature sensor and back to the tank. This is a continuous loop running all the time therefore putting no excess pressure on the main fuel injection pump.
The main water outlet from the engine is TEED several times to the veg tank, the main veg oil filter, the copper heat exchanger and the injection line heater.
June and July 2007.Again not much accomplished due to work commitments.
Automatic float vents installed with temperature sensor for pump control. They were installed to remove excess air.
Beginning to get a bit tidier now with partition in place but the batteries arrived so space had to be made. The 1500 pure sine wave inverter is for driving my heat pump and computer.
3 Kw pure sine wave inverter to supply house at night. New belts fitted to ST Generator and 24 vdc alternator. A smaller pulley was also fitted to the generator as well. This enables the engine to run at a lower speed but driving the 24vdc alternator considerably faster.
January 2008 Click to go to 2008
