Villiers 25HS powered generator

My first post here - I'm sure it won't be my last, good to be aboard!
Picked this set up a couple of weeks ago as a non runner. A 25HS and an Allam 230v 2kw alternator.
Now fully dismantled to assess its condition, and so far have found exhaust valve stuck open (bent stem!) Coil open circuit, and part of the exhaust cylinder casting broken.
Now some good news!
Looks like it been rebored (+.020) and hone marks are still very visible in the bore, oil was clean and very little sediment in the sump so basically I'm quite pleased with it. Found some dodgy threads which made the next size up and also some unusual threads which have turned out to be model engineer threads!
Have a spare parts list on its way along with a pair of crank bearings for starters as they seemed to be a bit rough I thought.
Anyone heard or know anything about Allam generators? The company was in Southend on Sea but have long gone. This generator's windings seem to buzz out ok but some of the insulation is a bit 'fragile' might need re covering.
Anyway that's a brief insight into what's keeping me out of trouble at the moment!

Alan

Hi Allen,

Nice to see the exhaust and air filter in good shape.
You can find a replacement (Taiwanese) coil fairly easily from vintage motorcycle suppliers or a pukkah job at about twice the price.

Thanks, the outer end of the exhaust is rusty but ok (it's in citric at the moment) but the flange end will need replacing as it quite badly corroded. As for the coil I removed it today for a proper buzz out and it is as I feared open circuit, replacement on the way. Condenser seems ok.
Found a nos exhaust valve on the bay which I was quite pleased to discover. The original was stuck open, I got it out but it was bent? The last 3/4 of an inch or so, thought about trying to straighten it but for £3.95!

Alan

Had a go at the cowling today as the wife was out and I could get it in the sink with a scourer! Scraped the worst out from the insides then hot water and washing up liquid made it much more 'handleable'. Took an abrasive disc to the outside and discovered a few dents but not bad for 60 years I thought.
While the filler in the dents was curing I stripped the carb and found the spindle very worn - .020 down from 1/4. Funnily enough the body seemed to have fared a lot better and has nylon bushes?
Considered making a new one but quite a lot of work so I had the idea of building the worn parts with silver solder. All cleaned up and rotating at about 200 rpm using the torch I managed to cover the worn areas (took more than one attempt) turned the new deposit down to size and it fits so much better!
Alan

As I had the carb in bits all over the bench I didn't want to start making a mess de rusting the insides of the shroud so I pressed on with carburettor assembly. The lug that the choke spring hooks onto was missing so I turned up a brass lug which was silver soldered to the arm for the spring to hang onto. The throttle and choke butterfly screws were assembled with a drop of thread lock, the petrol supply banjo bolt is a bit chewed up but I haven't got a better one so will have to do.

Alan

Taking shape Alan
RichieR

Not much happened today! I'm waiting for a parts list to be delivered so I can order any parts/gaskets I need, so in the meantime I'm working on 'ancillaries'.
Etch primed some sheet metal parts, the most memorable of which was the main engine casing which fell off it's support onto the grass just as I'd finished spraying it!
Didn't realise when I removed the points unit from it's base that the spring steel arm which holds the oiled felt pad has broken off.
Does anyone know if this part (it's riveted on) is available as a spare or should I consider making one? possibly from an old clock spring?

Alan

Alanengine wrote:

Didn't realise when I removed the points unit from it's base that the spring steel arm which holds the oiled felt pad has broken off.
Does anyone know if this part (it's riveted on) is available as a spare or should I consider making one? possibly from an old clock spring?

Alan

You could try here..

http://www.villiersparts.co.uk/ignition.html    - second row of pics.

PS Have manual / parts list if you are still waiting.

Woodsman, thanks for the link nice selection of parts including the spring arm!
I have a manual it's the parts list I am waiting for - is this something you could pdf across?

Alan

Alanengine wrote:Woodsman, thanks for the link nice selection of parts including the spring arm!
I have a manual it's the parts list I am waiting for - is this something you could pdf across?

Alan

My manual includes parts list? PM me with email address if you need a copy.

Woodsman wrote:

Alanengine wrote:Woodsman, thanks for the link nice selection of parts including the spring arm!
I have a manual it's the parts list I am waiting for - is this something you could pdf across?

Alan

My manual includes parts list? PM me with email address if you need a copy.

Woodsman, could I be cheeky and and have a copy of the manual please?

mattblack wrote:
Woodsman, could I be cheeky and and have a copy of the manual please?

Not cheeky at all. Sharing info and experience is why we are all here.
Manual sent.

As my new exhaust valve has turned up I thought I could at least grind them in in readiness, however I soon realised this was not to be as the exhaust guide is cracked!
When I took the head off the exhaust was stuck open, I assumed carbon but it was actually quite clear of major build up. Got the valve out to find the end of the stem was bent, not a lot but enough to make it difficult to remove and obviously the unsupported bottom end suffered the crack!
New valve is a good fit but I will have to change the guide.
Thanks to Woodsman I can now make a list of parts required - including valve guide!
Any useful tips for guide removal?

Alan

Woodsman wrote:

mattblack wrote:
Woodsman, could I be cheeky and and have a copy of the manual please?

Not cheeky at all. Sharing info and experience is why we are all here.
Manual sent.

Many thanks!

L & S have valve guides.

Thanks, in some photos it appears the guide has a 'head' and therefore have to come out in an upward direction.
Not keen on drifting it out as it's been in there a lot of years, has anyone had any good results with tapping the old guide and pulling it out with some studding screwed in?

Alan

Whenever I've had to change a guide I've just used a round bar turned down so it fitter into the guide and a hammer.
Put the new one in by freezing it overnight in the freezer and tapped it in

totally agree with our Stationary Engine Magazine pin up except I would make a puller to get it back in that way you dont have a chance of ovaling the guide with your hitting device or putting a crack in it.

Maryalice

[quote="maryalice"]totally agree with our Stationary Engine Magazine pin up

Maryalice [/quote]

Got your copy then....

'Stationary Engine Magazine pin up' gone totally over my head!
Years ago I used to get the Stationary Engine Magazine but I have enquired recently at a couple of good newsagents and was told it's no longer printed - is that right?

Alan

You can still get it, my local shop has it on the shelf and you can still subscribe...

https://shop.kelsey.co.uk/subscription/SEN

Appletop and I have known each other for several years and recently, a couple of years ago renewed that friendship and we have a friendly dig at each other, in this months Stationary Engine magazine he appears with one of his engines, he actually wrote the words as well.
Stationary Engine magazine is alive and kicking and has never been out of print, I see it in our local W H Smiths and my village store every month, If you google Kelsey publishing you can order your monthly copy on line.

Maryalice

Amazing, I specifically asked in WH Smith's in Basildon (quite a large store) which is one of the places it was no more!
I'll be back!

Alan

Placed an order for (hopefully!) all the parts and gaskets that I think I need, so tackled extracting the valve guides.
5/16 bore so tapped them 3/8 whitworth found a chunky washer screwed a piece of studding in and tackled the inlet first - it was tight! While under tension I gave the guide a clump with a brass drift which did the trick as I was then able to wind it out, same for the exhaust.
Also rang WH Smith's in Basildon and was told they don't take the magazine anymore - a decision from head office. However I found it was still stocked in the Southend branch and managed to pick up a copy.
Looking forward to a good read!

Alan

Did some tidying of the generator wiring this afternoon although will be replacing the output sockets as they have seen better days! Generally appears quite sound with good brushes and slip rings. Not been able to find anything about the Allam unit, particularly about it's wiring. It seems to use it's residual magnetism to initiate a voltage which is fed to the rotor and thus generate an output in the stator. The rotor wiring in corporates a couple of diodes, both seem ok, so is DC energised.
Love to get hold of some info on this unit or even a wiring diagram of similar generators.
Anyone any ideas?

Alan