The 1929 Austin 7 Restored by the Class of 2003 Studies in Product Configuration and Detailing
May 2003, M Des Programme Indian Institute Of Technology Delhi SPCD Class of 2003
Contents A. B.
A.
About the Austin The restoration 1. The car 2. The restoration Team 1. Students 2. The Workers 3. The budget 1. Assemblies 1. Engine 2. Body 3. Hood 4. Head lights 5. Radiator 6. Seats 7. Wind screen 8. Bumper 9. control Photo Gallery 1. Progression 2. People pictures 3. Final Austin
SPCD Class of 2003
About Austin As far as we know the 1929 Austin seven came into the possession of the institute in the early days when IITD and the Imperial College in London exchanged faculty. For years this car was IITD’s entry for the annual vintage car rally organized by Statesman. A decade or so ago this practice was discontinued and the car lay forgotten in a corner of the student activity center. As a part of 2nd semester academic curriculum, the restoration of this car was taken as an exercise in the course Studies In Product Configuration and Detailing. The class was 15 students strong and each student took up one area to restore.
SPCD Class of 2003
About The Austin
SPCD Class of 2003
SPCD Class of 2003
What it may have been !!! Austin Seven in its Original Condition
SPCD Class of 2003
Austin History An Idea develops….. In 1920 Sir Herbert Austin commenced working on the concept of a smaller car mainly to meet the needs of young families aspiring to own an affordable motor car. This idea was spurred on by the depression throughout Britain and the Horsepower Tax (£1 per RAC horsepower rating) introduced in 1921. This marked a departure from his company's conservative motoring past. Austin received great opposition from his board and creditors for this new project and decided to finance the project himself. In 1921 design work was underway in earnest and Austin hired an 18 year old draughtsman, Stanley Edge, from the Austin factory at Longbridge, Birmingham to aid in the drawing of detailed plans. This work was carried out in Austin's billiard room at his Lickey Grange home. Austin's main talents were in his styling ability and determination. Stanley Edge complimented Austin and after time convinced him to use a small four-cylinder engine. The original side valve engine design featured a capacity of 696cc (55mm x 77mm) giving a RAC rating of 7.2 hp, the cast cylinder block featured a detachable head and was mounted on an aluminium crankcase. The crankshaft used two roller bearings and was splash lubricated. Edge also carried out the design of other mechanical components such as the three speed gearbox and clutch assembly. Austin was largely responsible for the balance to the seven design. The Peugeot Quadrilette and Bébé reportedly influenced his design. The "A" frame chassis design was believed to be borrowed from an American truck used in the Longbridge factory in the early 1920's. One major difference was the four wheel braking system (independent front and back) design by Austin. The design was completed in 1922 and three prototypes were soon being constructed in a special area of the Longbridge factory. The Seven was finally announced to the public in July 1922, and was dubbed the 'Chummy', the term reportedly referring to the car as a Chummy friend (the term was also used to describe the disposition of passengers so close together !). The purchase price was a mere £165
SPCD Class of 2003
A slow start…… Sales were slow in 1923 with 1936 Chummies being produced. In 1924 the engine capacity was increased to 747cc (now 56mm x 77mm) and production jumped to 4,700. Other refinements included an electrical starter motor, a cooling fan and a speedometer. The first Austin sports model was also introduced in 1923. By 1926, the project was considered a success when production passed the 14,000 figure. A saloon model was produced in this year with the Austin Motor Company offering a fabric covered body model in the following year. In 1928 another variation known as the 'Top Hat' was produced. Other changes introduced were an ignition coil (replacing the previous magneto system), uncoupled brakes (until 1930 when the foot pedal operated both front and back) and nickel plating of the radiator shell. Employee commitment and loyalty was important to Herbert Austin. The Seven matures…… The 1930's saw numerous small changes such as an increased wheelbase (to 6 feet 9 inches - from 6 feet 3 inches), the fitting of trafficators, larger brakes, wider tyres, the introduction of a four speed transmission and the moving of the petrol tank to the rear of the vehicle. With the relocating of the petrol tank a mechanical petrol pump was also added to the Seven's engine. Other interesting features such as the Moseley 'Float-in-Air' pneumatic seat cushion were offered on numerous models in the 1930's. Two new models the 'PD' (forerunner of the Opal) and the Sports 65 were added to the range in 1933. The 'PD' two seater model sold for the low cost of £100. The Sports 65 featured a lowered chassis and engine improvements providing almost twice the horsepower of the standard Austin of the dayThe Sports 65 was renamed the Nippy in the following years. Two further models, the Ruby and the Pearl Cabriolet followed in 1934. The Ruby had great sales success, it featured styling changes including the radiator being relocated behind a cowl and bumper bars. Over 27,000 Austins were produced in 1935 making this year the best in history in terms of Austin Motor company sales. Sir Herbert Austin was reportedly paid a royalty of 2 guineas per car produced from 1926. The Seven over the years was available in a wide range of colours depending on the model. In 1936 major changes to the engine and brakes were introduced. The motor now featured three main bearing
SPCD Class of 2003
and a new head design (using 14mm spark plug), the horsepower developed was now 17 hp. The old style cable brakes were replaced with modern Girling brakes. The new Big Seven with it's 900 cc engine was introduced in 1937 to replace the aging Seven. Sales figures were excellent for the Big Seven, doubling those of the original Seven in 1938. The final Seven was produced in January 1939, the engine however remained in production until the early 1960's being used in other small vehicles such as the Reliant, a tribute to a successful design. In all over 50 different body designs came out of the Longbridge factory between 1922 and 1939, many of these being of a commercial or military nature. Many Australian bodied Sevens were also produced from the mid 1920's to the late 1930's largely to support the local coachbuilding industry in Australia. The Austin was also produced under license by the Dixi company in Germany, later to become BMW and in France by the Rosengart company. The early design of the Japanese Datsun was also influenced by the Austin Seven.
The less successful Bantam was produced by Austin America. Many British body designs were available from coachbuilders during this time. One of the more noted being the Swallow version of the Seven built by William Lyons, who later designed the first SS (pre Jaguar) cars. Another interesting variation of the Seven, in a left hand drive format, was produced by the Willys-Overland, Crossley company in England and Germany. The Seven has a long motor racing history starting with the humble Seven sports in the early 1920's trough to heavily modified Sevens becoming the foundation of Lotus in 1948. The Austin Seven, or at least parts of them, formed the basis of many other inventions over the years. One of the most interesting examples of this is the Austin Seven engine being applied to the field of aviation. Another application was the use of the Austin Seven engine in motorcycles. Austin built tractors at Longbridge between 1919 and 1926. A second factory was opened at Liancourt in France which continued making Austin tractors until the end of World War II.
SPCD Class of 2003
Austin Advertisements
SPCD Class of 2003
Austin Advertisements
SPCD Class of 2003
Austin Advertisements
SPCD Class of 2003
Badge and Logo
SPCD Class of 2003
Meters
Speedo Dial MA
SPCD Class of 2003
Ampere Meter (Joseph Lucas) 20-0-20 Amp
Oil Gauge (Harcourt) 010psi Scale
Petrol Gauge (Smiths) 0-5 Gallons
Petrol Gauge (Smiths) Empty-Full
Suspension Details
SPCD Class of 2003
Austin 7 Dynamo cicuit
SPCD Class of 2003
Wiring Diagram
SPCD Class of 2003
Dynamos/Generator Circuit
SPCD Class of 2003
Austin Seven Colours
SPCD Class of 2003
Austin Seven Colours
What colour is that seven? From Bill Sheehan "The Lightshaft' Victoria, Australia - June 1974 as it appears in the "Austin Seven Companion" by the 750 Motor Club Many people ask for details of correct colour schemes for the various models of the Austin 7. Let me say first that you paint your car the colour that you prefer, but naturally most people prefer to follow the original colours when making a choice. When discussing original colours the issue is clouded somewhat in that the many body manufacturers of the day (particularly in the late twenties) produced body and trim schemes well away from the standard factory colours.
SPCD Class of 2003
What colour is that seven? Likewise in Australia we had some colour (particularly Bright Red) which didn't coincide with the English -produced Chummies. It might be opportune to mention here that there is virtually open licence on sports and van bodies, more so the latter. Here is a selection for your guidance, the non-factory ones being indicated. 1923-5 Chummies - Black, Pole Blue, Royal Blue, Maroon 1924 factory sports - Kingfisher Blue. 1924-7 "Brooklands" Sports (Gordon England) - Polished aluminium. 1926-7 G. England "Cup" sports (fabric) - Scarlet, Royal Blue, Mottled silver and black, orange and green, nickel radiator. April '26 G. England's fabric saloon - grey, red or dark blue, all under black. October 26 factory saloon (metal) - primrose and black. 1926-30 Chummies - Black, Pale Blue, Oxford Blue, Red, Maroon, Dove Grey, Dark Green. Sept. '27 (1928 models) G. England's fabric saloon & Cup sports - Orange, Dark blue, Maroon, Brown, green, with brown hide upholstery. 1930-31 "Ulster" sports - Cream body, green wings, black upholstery, hood and wheels or Black body, hood, wheels, red wings and upholstery or Red body, black upholstery, wings, hood. 1933-6 "Nippy" and "Speed" sports - Primrose, Torquoise Blue, Cherry Red, Black. 1933 etc. "Opal" roadster - Royal Blue, Dove Grey. Ruby saloon - Royal Blue, Maroon, Westminster Green, Black, Torquoise, Blue, Dove Grey, Pueblo Brown Ruby fixed-head saloon - Royal Blue, Maroon, Black. "Open Road" tourer - Royal Blue, Maroon, Auto Brown. March '37 Pearl Cabriolet - Cherry Red, Royal Blue, Westminster Green, Ash Grey, Black.
SPCD Class of 2003
Engine specification Bore 2.2" ( 55.88 mm) Stroke 3" ( 76.2 mm ) Capacity - standard Compression Ratio ( up to mid 1936 ) Compression Ration ( post mid 1936 ) b.h.p. 1922 b.h.p. 1923 1932 b.h.p. 1933 - 1934 b.h.p. - 1935 b.h.p. 1936 b.h.p. 1937 Timing Pre 1935 1 7/8" B T D C Mk1 Ruby engine Firing Order Contact breaker points 1929 - 1931 Contact breaker points 1932 - 1936 Contact breaker points 1936 - 1939 Champion No 7 Sparking Plugs Champion L10 Sparking Plugs Sparking plug gap Valve clearances Inlet - standard engine Exhaust - standard engine Inlet - sports engine Exhaust - sports engine
SPCD Class of 2003
Austin Seven Engine Data 747.5 cc 4.8 : 1 6:1 10 @ 2400 rpm 10.5 @ 2400 rpm 12 @ 2600 rpm 13.5 @ 3000 rpm 16.5 @ 3400 rpm 17 @ 3800 rpm ( 20 degrees ) 3/4" BTDC at flywheel 1342 0.020" 0.014" 0.012" 1922-1936 1936-1939 0.018" to -0.020" 0.004" Hot 0.004 Hot 0.004" to 0.006" Hot 0.006" to 0.008" Hot
Sports 24 @ 5000 rpm ( 1930 Sports 21 @ 4400 rpm Sports 23 @ 4800 rpm Sports 23 @ 4800 rpm Sports 23 @ 4800 rpm points should be just opening CAV electrics Lucas electrics Lucas electrics Low compression engine High compression engine 0.006" Cold 0.007" to 0.008" Cold 0.008" Cold 0.010" Cold
Big End Bearings Standard engine Not pressure fed Big end clearance to crank pin Crank pin out of round Big end nuts torque Small End Bolts Small end bolts Camshaft End float
Austin Seven Engine Data 0.002" to 0.002"
Optimum clearance 0.003" around 20 ft. lbs.
Bolt Heads should face off-side of engine
0.002"
Lubrication Normal Oil Pressure - 2 bearing crank up to 5 p.s.i. Normal Oil pressure - 3 bearing crank up to 5 p.s.i. Oil filter Gauze in sump clean every 4000 - 5000 miles Oil grade S.A.E. 30 or equivalent ( avoid detergent oils ) Sump capacity standard engine 4 pints Sump capacity sports engine 8 pints Cooling System Capacity 9 ½ pints approx. Pistons & Rings Split skirt piston Piston to cylinder clearance Piston to cylinder clearance
SPCD Class of 2003
.0015" .004"
Split on nearside of engine Split skirt piston w Plain skirt piston w
preferred maximum
Technical Data Austin Seven Gearbox Data Lubrication Oil grade - standard Oil grade - sports Oil capacity 1922-1932 Oil capacity 1933-1939
Chassis and Suspension Data Front Springs 1924-1925 1926-1929 1929-1934 Rear Springs 1924-1925 1926-1934
SPCD Class of 2003
S.A.E. 40 S.A.E. 50 2/3 pint 1 1/2 pints
engine oil.
5 leaves 5 leaves 8 leaves
30" bush ce 29 1/4" bush centres 29 1/4" bush centres
6 leaves 7 leaves
23 1/4" hole to bush centres 23 1/8" hole to bush centres
Austin Original Chassis Drawing
SPCD Class of 2003
Austin Original Chassis Drawing
SPCD Class of 2003
Austin Original Chassis Drawing
SPCD Class of 2003
Austin Original Chassis Drawing
SPCD Class of 2003
Restoration team Assembly
Students
Engine Body Hood Front section Radiator/ cowl Seats Wind shield Rear Section Controls
Sarvesh, Abhishek, Prashant Amarjeet, Ramesh, Shaun Charudatt Umesh Purvag Nanavati Dhanasekaran Kanchan Harne Sutapa Pati, Aditi Amol
SPCD Class of 2003
Engine
Abhishek
SPCD Class of 2003
Prashant
Sarvesh
Engine Our Austin Seven was a car donated by the Britishers to one of the professors of IIT Delhi. He then donated it to the Mechanical Engineering department for the students to learn the basic fundamentals of the automobile. The car gave all that it could to the students untill it was of no more use and during the last days of its life, it stood in the Students Activity Centre. It was a few years back that a professor from the Industrial Design Department, knowing the value of the car to IIT, got it to his department to restore it. And thus the story of its rebirth begins......
SPCD Class of 2003
The Engine The Engine was in the worst of its conditions. Many of the important parts were missing. The most important of it were the complete radiator and many carburetor parts. In the first go, the aim was atleast to get the engine running. Parts were looked up in the Students Activity Centre but none of them were found. Looking for Parts Like Jama Masjid Motor Market in Taj Hotel, Mayapuri, Connought Place, Khan Market were scanned to get the Austin Parts but they are very rare and we have to either import it from England or duplicate them here..
SPCD Class of 2003
Engine Condition
Starter Gear Radiator Missing
Distributor, Alternator SPCD Class of 2003
Carburetor (Incomplete)
Inlet & Exhaust Manifolds
Engine Condition
Voltage regulator, Distributor
Starter Motor Gear box SPCD Class of 2003
The Engine
Engine Head
Starting with the Engine !! The Engine work was started by first cleaning it. The Chassis was also cleaned before this. Cleaning was carried out by using kerosene, sand papers, scrapers, etc. Now the engine looked better than what it was earlier and our hopes of getting it started still increased. By cleaning it we could get a clear idea of its real condition and also we could get some important details like its engine number, gear box number, etc.
Cleaned Engine and Chassis
SPCD Class of 2003
The Cylinder Story Once the outer part of the engine was over, the work of opening up the engine started. It started off with the cylinder head which came out easily. And as we removed the head....we were taken aback......it was the most surprising scene. The cylinders were packed with rust, rust, scales, etc and we could also fine some rusted nuts, etc. in it. So now we had a huge task of cleaning it up and moving the pistons.
The Head
Rusted nut
Rust & Scales
SPCD Class of 2003
Alas ! They Move The most time consuming job was opening up the jammed pistons in the cylinder. It took five days to make them move by a millimeter. First, it was tried out by wetting it with kerosene and giving jerks to the engine by moving the chassis forward and reverse. This did not work. We had a thought that the engine would never work. Anyone would say that. Then the cylinders were soaked in petrol for 3 days and then again jerks were given to the engine. After about four hours of hard work on the engine, the pistons stared moving thus making it a day. This was the most enjoyable achievement..
The Pistons are now free to move
SPCD Class of 2003
The Cylinder Block After the pistons started moving, the cylinder block was taken out. It was rusted from Inside and may need re-boring. The gaskets need to be changed. The cooling water inlet manifold was found cracked.
SPCD Class of 2003
Valves and Manifolds Being robust and cast, the manifolds were in good condition. The valve seats were rusted and it took time to loosen the valves and make them moving too. Other things that were covered like springs and tappet were safe.
Rusted valves and seats
Exhaust Manifold
SPCD Class of 2003
Springs and tappets are OK
Fuel Inlet Manifold
Engine Drain The worst job of all which made our clothes the most dirty was this one. The engine was filled with 6-7 liters of bad oil and an equal amount of water. But still the parts inside remained safe without damage and rust. The lower cover had a thick layer of dirty sediments. There was a filter which filtered the oil. The drain plug was of no use for draining as it was jammed due to rust. So we had to remove the lower cover to drain.
Drain Bolt
Lower Cover
SPCD Class of 2003
Bad Oil
Lower Cover
Sediments
The Underside The underside has a oil filter. And a pump (not sure). The gasket needs a change here too. Rest of the parts here are safe due to the oil. Now there is not much work left to open up in the engine and only cleaning the engine is required before repairing it.
Gear Box Drain Plug
Gasket
Oil Filter
Oil Pump (not sure)
Oil Pump (not sure)
Oil Filter
SPCD Class of 2003
Gears The cam shaft is in good condition except some parts that are missing. These include a pulley to drive the cooling fan and its fittings. Gaskets etc. To be changed. The gear box was opened up to check the condition. All is fine here except an oil change. Also a pin of the operating lever was broken which needs a repair. No further work is needed on the gear box as it is found OK
Cam Shaft and Gears
The Gear Box SPCD Class of 2003
The Gear Box
Alternator and Distributor Being an electrical part, needs repairs. One of the fan blades is broken. Spark plug wires needs change. These were given to a mechanic in Lado Sarai for repairs.
Hand Starter Gear:1 All parts are found in acceptable condition. The lever for starting the engine is missing.
SPCD Class of 2003
The Silencer The silencer is in a very bad condition. It has cracks all over and the metal has rusted badly. Also the connecting pipe from the muffler to the exhaust manifold is missing. The silencer needs a considerable work. May be we need to make a new one.
SPCD Class of 2003
Body Work
Ramesh
SPCD Class of 2003
Amarjeet,
Shaun
Body work The car had no cowl. Apart from the body work was in very poor state. The mudguards have been repaired in the part and this work had not been done very well.
SPCD Class of 2003
Ventilator missing Corroded underneath
No cowl
Aluminum body Patch Patch Rear section notched up
SPCD Class of 2003
Corroded
SPCD Class of 2003
Images of mudguards after detached from the body
SPCD Class of 2003
Hood
Charudatt
SPCD Class of 2003
Hood When I started working on hood it was in its worst conditions. It was heavily damaged. 1. The links were bended so its mechanism was not functioning. 2. All parts were rusted and there was a lot scaling. 3. There were number of dents and fissures. 4. Rivets were rusted and worn out that’s why there was a lot of play between links. 5. Some rivets were missing 6. Some links were broken and hence mechanism was nonfunctioning. 7. The top canvas/leather was missing. 8. Fasteners to fix the hood to car body were missing
SPCD Class of 2003
Restoration without debasing heritage and vintage value that was the aim of this project. We started our work with a lot of zest but after few days it became slowed down reason for it remained unanswered. Though it can not be completed in semester period I keep hopes to complete it in this summer vacation. Task given to me was to restore the hood. Steps in direction of that were • •
• •
Information collection on internet Correspondence with many alumnus through email and telephone includes Sugandh, Ajay,Timex,T.Vinit, Prof.B.K.Chakraborty, RoyalEnfield etc. for funds and other helps. Estimation 1500. Cleaning of the hood, removing scale and dirt with help of wire brush
SPCD Class of 2003
• • •
• •
Removed the stain using kerosene and put oil in the joints for the better movements. Removed some of the nut bolts which were badly damaged and jammed. Several time visited to the various car owners and car restorers to get some kind of ideas and information. Welded the broken links with help of Trilochan. Removed bends and welded some of rivets which were worn out.
SPCD Class of 2003
lamps
Umesh
SPCD Class of 2003
Lamps The lamps consists of the following components •Reflector •Lamp •Lens •Outer rim •Lamp casing •Bolt fixtures •Wire connecting the lamp and battery •Battery
Photograph of restored Austin
Electrical data
SPCD Class of 2003
Methodology of Replication : 1. 2. 3. 4. 5. 6. 7. 8. 9.
Net Search for photographs and literature on headlamp restoration. Product component study of locally available old headlamps. Search for an original Austin seven 1929 headlamp. Taking measurements and documenting of the headlamp. The bodies, rims and reflectors are spun from sheets of brass onto specially made wood or nylon formas using a lathe Making the wooden mold for spinning of lamp outer cover and the reflector. Metal spinning- The body of a headlamp is spun on a lathe with intermittent heating (ANNEALING) to help form the required shape and size. All internal fittings, hinges, brackets even stone guards are then made. The lamp pieces are then electroplated and finally constructed to give a lamp of unsurpassed quality.
SPCD Class of 2003
Cost estimation: Spinnig Painting Lense Lamp 600/Electrical connections (excluding the battery) Miscellaneous Total Contact persons – Mr. R.P. Sharma Guru Nanak Spinning Works (O) 25743052 M-24A, Gali No. 7, Anand Parbat Indl. Area, New Delhi-5 guruap8@delhi-industry.com
SPCD Class of 2003
Rs. 2000/Rs.1000/Rs. 600/Rs. Rs. 500/Rs. 1500Rs. 6,200/-
Front radiator, Radiator grill
Purvag
SPCD Class of 2003
Front radiator, Radiator grill How is it? In the last ten years this car saw worst days of it. All the parts except frame and engine were stolen or removed. Same thing happened to front cowl and radiator also. Both the things were either stolen or removed. There was nothing left on the front side.
The pictures above reveal the condition of the car when it was brought for restoration.
SPCD Class of 2003
SPCD Class of 2003
SPCD Class of 2003
Approach First I started with gathering information of the original car and parts. The parts which are to be restored as below: 1. front cowl 2. radiator and radiator grill 3. radiator tank 4. Austin badge 5. Austin logo The front cowl is made from brass. So the first step was to get the original drawings and dimensions of the cowl. After getting the dimensions the first step is to make from nuwud. Then the brass will be dented on the nuwud cowl. Thus the final cowl will be achieved. For the radiator a radiator will be made from the fiat radiator. And radiator grill will be of expanded mesh. The Austin logo will be photo chemically itched form the drawing. The Austin badge will be itched also. The cap will be machined form the shaft. Contact addresses: For the denting and cowl work Mr.Gyan Sharma of Krishna motor garage is willing to help and he has given an estimate of 8000. He is also keen on radiator part also. He has an extra Austin logo which he can sell to us. He said his workshop can also make a radiator cap but with the dimensions the same thing can be done in the college workshop also. Mr. Gyan owns the same Austin model. So I visited his place with Trilochan (carpenter) to get the exact dimensions. Now as the wood cowl is almost finished one more visit is required to finalize the exact dimensions
SPCD Class of 2003
Contact addresses Gyan Sharma Krishna Motor Garage M-46, Connaught Place, New Delhi 110 001 Ph (o)- 2332 5358, 2373 9734 (r)- 2714 3859 Cost involved: For complete front cowl of Brass cost will be around 7000 – 8000 The radiator will cost around 3000-3500 including labour charges. And for the other part the material is purchased. The logos can be itched in the labs only.
SPCD Class of 2003
Seats
Dhanasekran
SPCD Class of 2003
Introduction: As a part of “studies in product configuration and detailing� I worked on the Austin car seat. The car contains three types of seats. Two seats for front and one for back. The front seats are identical in size. The back seat is long and it made up of wooden frame. The car seat was fully damaged it has 4 covers over the cushion. The springs are got rusted. There are 16 spring in front seat (in one unit). The springs are conical type springs. They are fixed in the wooden base plate and tied using threads. The back rest is made up of MS sheet. Using press die they manufactured that. It is curved in shape. By butt weld method the back rest is joined in base. The back rest is damaged because of rusting. The cover on the top is deep red in color. Using coir and cotton they prepared the seat cushion. The seats are hinged in the frame. The frame is bolted in the base of the car. We can move the front seats towards front.
SPCD Class of 2003
Materials required for restoration: •Springs •Rexene •Coir and cotton •MS sheet •Threads
- 16+16+20 - 15m -3 kg each
Places visited: Gurgoan to find sheet metal experts Jumma Masjid to search old springs Southex to find out sheet metal experts IIT workshop for sheet metal work IIT maintenance unit for cushion work And I collected many useful documents about car restoration and Austin car parts. With this report I attached the collected documents and photographs.
SPCD Class of 2003
Windshield
Kanchan Harne
SPCD Class of 2003
Windshield Procedure: In my share were the mirrors, wiper, horn and the windshield. From this all the parts ie the wiper horn and mirrors were all missing. so for this I searched on the net as to how the parts were. After observing the holes etc provided on the frame of windshield it was found that all these parts were attached to the frame of windshield. The parts are 1. One mirror one rectangular attached in the centre. 2. One circular attached to the other side 3. A tiny wiper was provided on the windshield in front of the driver’s seat, 4. A blow horn a typical kind used in earlier days on the right side so easy to blow 5. The windshield with the glass which was in good condition. 6. The aluminum frame 7. The supporting rods of iron
Windshield
Holes for screwing other parts
SPCD Class of 2003
Procedure All the parts were fitted with simple screwing arrangement. The horn was on the outside on the right side a typical blow horn in some cars it was a little decorative also. The windshield was in iron chrome plated with rubber gasket and glass which could be tilted so as to open it. The mirror is usual one rectangular and one circular. After doing the study through net and getting the details of the parts I went to Jama Masjid Chandani chowk where you get all these parts in second hand and if you are lucky you may get the original parts also. So there I bought there the blow horn and the mirrors of similar kinds these purchases were of about 100 Rs. These were to get the finished look for the car.
Glass as seen in good condition SPCD Class of 2003
Procedure The next thing was to restore the windshield. The windshield was removed from the car. It was fitted with simple nut and bolts. The bolts were junked and oil was had to be put to loosen it. It had to be then removed with care so as to not to break the already junked screws. The threads were all smoothened due to junking. A little use of sand paper made it easy to remove. The nut bolts were then marked properly as the right and left and kept in separate poly bags to use later.
Holes for Mirror/ horn
SPCD Class of 2003
The typical blow horn as seen
Wiper in front of driver seat
Budget The restoration of each part required some amount of work to be done so as to reuse. The following chart will give the work needed to be done for this. For the restoration of the different parts a chart was made which gave the details of the procedure and then the budget was found out for it.
Part
Cost
Windshield a) Glass The glass is in good condition so it had to be cleaned and restored. For cleaning it can be done by rubbed the glass cleaning white powder with a soft cloth. This will require buying of the powder. Glass cleaning Powder
30 Rs
b) The supporting rods: Made of iron cleaning by sand paper and de-rusting and then chrome plating it. This can be done in okhala industries if good finish is required or locally done near Dhaula kuaa, Moti bagh crossing, in front of Hayyad Hotel (palika bhawan). The chrome plating is a chemical process so it will require through cleaning of the rods and then the rods would be dipped in electrolyte solution kept in chamber in which electricity is passed at about 400deg cel to 1300 deg cel it reacts.Chrome plating done at the rate of 1.50 Rs per sq inch depending on the quality of finish so approximately
400 Rs to 500 Rs
c) Aluminum frame: This is also in good condition it would just require cleaning and restored
SPCD Class of 2003
50 Rs
Budget d)The rubber strip It has to be replaced for the fitting of glass
250 Rs.
2. Horn: The horn if taken simple one would cost about
Rs 30
A little intricate one with brass finish would cost
Rs. 100
3. Mirrors: The two mirrors one rectangular and the other circular
Rs. 100
4. Wiper: The wiper was not taken into consideration as it was very difficult to get that kind of wiper out of manufacture and use.
NIL
5. Fitting Accessories: Fitting accessories like nut bolt for the fitting of mirrors and horn. For horn rod or some arrangement would have to be done welding etc would be required.
Rs. 150
Total Expenditure
Rs. 810
SPCD Class of 2003
Steering and controls
Amol Bagade
SPCD Class of 2003
Steering and controls Four bar steering mechanism is in working Order. Gear and gear shifter assembly working. Warm steering gear is well lubricated and in working condition. Problems: -Rusty steering -Horn and steering cover is missing -Steering gear hub cover cracked -Thread on nuts and bolts are flattened
SPCD Class of 2003
Breaks and Break cables Break\ clutch and accelerator pedals are in working condition. One side rear break cable is operating. Three pairs of break shoes present. Problems: Broken right side rear break cable Front right break shoe pair missing Joints and fasteners are rusty Hand break assembly missing
SPCD Class of 2003
Restoration-Â procedure, costs Effort is made to retain all of the old components, although in more damaged cases such as break cables entire replacement is necessary. A steering and controls can be looked at in four main sections: Steering wheel\ link mechanism Gear lever Accelerator\clutch pads and cables Break levers \ cables \ shoes Step 1 Each component part is taken out of the steering assembly Step 2 Cleaning of parts in kerosene to remove all the mud out of it. Step 3 Inspection of the part for damages Step4 Restored and refitted the components in sequence Step5 (Incomplete activity) Replacement of wear out parts
SPCD Class of 2003
Costs No.
Component name
Quantity
Approx. cost (Rs.)
1
Break cable
1
300
2
Break shoe
1 pair
200
3
Horn
1
500
Total
1000
Motor works Contacts 1 Anand Saluja Cell: 9810328361 Shri Balaji Car 2269/66, Nai Wala, Karol Bagh, New Delhi 110005 2 Ravi Gopal Krishnan Cell: 9810478869 Laxkmi Motor Works Sujan Singh Park
SPCD Class of 2003
The work done by us
SPCD Class of 2003
The work done by us The work done by us: The Vintage Car restorers we met. Bharat Usha Motor Garage, Archini. We met Bharat first and got to know a few dealears and clubs in delhi that help in restoration of vintage cars. Bharat came over to IIT and looked at the car gave and estiamate, said the cost would come up to about 40,000 Rs for the entire restoration except the engine, we did not go back to Bharat though. Ravi Gopala Krishnan Laxmi Motor Works Ph: 98104 78869 We had met Ravi Gopala Krishnan, in Sujan Singh Park, an antique automobile restorer who had given us good information regarding Austins, told us restorations techniques and important links to working on the Austin, chummy Ravi gopal suggested to do the chummy body himself in the workshop, the car body had to be transported by truck to his workshop, where his people would work on it there. We brought Ravi Gopal to IIT Delhi, he had a look at the car and gave an estimate of 25,000 Rs for the complete body work, including the paint job, Ravi Gopal had agreed to give a man for the Denting and Fabrication job of the Chummy, to save costs a man was to come and work here in IIT at the cost of Rs 400 per day, the wages included him and his helper. A trip to Ravi’s work shop was organized, the 15 students went to Sujan Singh park and had a look at various cars being restored and asked questions, to find out more information regarding working on their parts of the project, Ravi took us to the Hinduja’s house near by where we saw an Austin ruby, the class clicked pictures of the Austin Ruby and studied it detailing. Repeatedly went back to Ravi and asked him for the man for the fabrication work, he kept promising week after week, but the man never turned up.
SPCD Class of 2003
Shivaji Samaddar Manager Delhi, The Statesman, Statesman Building Shivaji_samaddar@hotmail.com Ph: 23315911 to 17 Went with Sarvesh to the Statesman building and met the statesmen people, they organize the vintage car rallies, so he listened to us and was very encouraging, and took down our email id’s and phone numbers and promised to get in touch with us, giving us contacts of owners of Austins Cummy’s and also that they will help us with spare parts and information. Gyan Sharma Krishna Motor Garage, Connaught Place, Ph:2332 5258 Gyan is a Austin Chummy owner the very same model of the IIT Austin, and also takes part in rallies, with his Austin, this was a lucky break cause was got to see the exact Austin, that we had to restore to, Gyan also showed us other Austin models, We went back a couple of times to meet him and arrange a trip of the entire class to Gyans’s Austin, the trip never materialsed together, but some of the people in the class ended up meeting him and seeing the austin. Gyan agreed to help us in giving us details and information and also guiding the class, he also said the the class people can come and work in his garage so as to save on labour charges and also to do the work ourselves, Gyan was helpful but he wanted the Austin body to be brought to his garage, he was not willing to send any men to do the work in IIT.
SPCD Class of 2003
Tutu Dhavan E- 366 Greater Kailash II Ph: 98110 22122 We went to Tutu Dhavans house and met him in the evening, he was an arrogant old man and seemed the wealthy type, he could tell me nothing till he saw the car, or at least pictures of the car, so the next day I went to his house with the pictures of the Austin burned on CD, and gave it to him, he told me to get back to him later, I phoned him up the next day and he gave me an estimate of 1 Lakh for the restoration of the car body alone, he refused to do half the work and he said that he would not do half the work or let the students touch the car, he wanted to do the entire paint work himself, so I went back the next day and got the CD back from him.
SPCD Class of 2003
Appindix-1
SPCD Class of 2003
Some intresting website on Austin seven www.austinsevenownersclub.com www.krbaker.demon.co.uk/britcars/a/austin.html www.geocities.com/MotorCity/4752/ www.homepages.tig.com.au/~bayo www.homepages.ihug.com.nz/~sweetpea/a7.htm www.austin7.motorpage.com www.theaustinseven.com www.austin7club.org/ www.austin7.ipfox.com www.members.tripod.com/~jlrover/austin50 www.austinworks.com www.ba7c.freeserve.co.uk www.ea7c.co.uk www.austin7.org www.austintendriversclub.com www.mcmillan80.fsnet.co.uk www.fbhvc.co.uk www.motormuseums.com www.britishpathe.com www.iwsteamrailway.co.uk www.iwight.com www.islandbreaks.co.uk www.invectis.co.uk www.iwcp.co.uk
SPCD Class of 2003