Fabricating intricate Model T parts to last for generations

[AdminJeff]

DISCLAIMER: I'm not plugging these parts - I'm simply relating the story of the time, energy and expertise that went into creating them, and this will likely be of interest to many people.

Most folks look at Langs, Snyders, and other vendors websites and peruse the products they offer without much thought of what went into creating all those specialized products for vehicles that are 100+ years old. Passion, time, perseverance and dedication to our hobby invariably went into most everything listed in those catalogs. Created by dozens if not hundreds of people who are dedicated to keeping these amazing cars on the road. Nobody's getting rich off of selling parts to T owners, the cheapest SOB''s on the planet. I should know, I'm one of them!

I started this journey in January of this year to create what does not exist. As you all probably know by now, I'm an expert at rebuilding starters and generators having done literally 100's of them at this point.. I often found myself cursing the quality or unavailability of certain rebuild parts for these units.

My first goal is to reproduce all parts necessary to rebuild starter & generator brush holders with ALL NEW components at the highest quality possible. 10 months later and I'm almost done with this first phase. I had no idea at the time just how much work it would take to accomplish this goal. But I persevered and overcame all the obstacles, and there were many. I'm an accomplished engineer and am no stranger to creating engineering drawings and product specifications.

Those are one thing. Getting specialized vendors to produce high-quality, usable parts from them is another thing entirely, sometimes having to start from scratch with a new fabricator. It's not sexy stuff. In fact you can't even see the parts I'm producing for your car. But all cars produced from 1919 to 1927 (and many others) need these parts to keep running, both now and in the future. Somebody had to do it. I'm doing it....

Im creating rebuild kits to refurbish starters and generators with all new parts. Everything needed to rebuild these units. I even sourced 2ml vials of Loctite (have you looked at your dried up Loctite bottle lately?)

• Brush holders molded and die cast from Zinc (not pot metal as was done in the originals)

• Brush plate insulators laser cut from FRP that fit perfectly and are 1/32" thick

• Brush holder backing plates laser cut 1/32" thick

• Brush holder springs of the correct tension perfectly molded & shaped for both starters & generators

• All the correct hardware necessary for the rebuild - rivets, screws, Loctite etc

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Once implemented, these components produce these completed brush holders - again with ALL brand new parts:
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Using the parts I fabricated and starting with a blank starter brush plate it took me all of 10 minutes to fully assemble what you see in the picture above. Anyone whose done this before knows it normally takes a few hours of work to clean & massage all the used parts into a useable rebuild.

All of this work will be coming soon in kit form to a vendor near you.

Up next: brushes and field coils. A good winter project. My goal is to reproduce ALL parts for these critical components, at the pinnacle of quality and lowest cost possible.

Jeff

[TXGOAT2]

Thank you!

Ford was able to make a little money per unit on these items by ordering or producing millions of them, and doing so as efficiently as possible.
Things are much different today.

[Daisy Mae]

Having been in the T hobby twice now in my life at two periods of time (80's and now), I was surprised at the difference in parts availability....very unsettling...

I applaud you, and everyone else in like shoes, who make such an effort to keep our babies on the road.

I also own an A, and you can only imagine how much excitement Burtz new engine blocks created. Fascinating read as to his efforts & journey.. Like you, it takes passion, motivation, perseverance, at your own expense....we are very fortunate those like you exist.

[John kuehn]

Now that’s a good idea! As time goes on small necessary parts will wear out or get thrown away.
Thanks!

[Steve Jelf]

Nuts & bolts. You can buy the modern ones at a hardware store, grind off the markings, drill cotter pin holes, and get something similar that show judges won't notice. But compare an original bolt used by Ford and an adapted modern substitute. The difference is obvious. As far as I know, there is nobody reproducing the originals. Most of us don't even recognize the difference, but once you do it's hard to miss.

[AdminJeff]

No offense Steve..... but I personally have zero interest in reproduction bolts and some judge's esoteric opinions on said topic, but I do care about being able to reliably start your car and actually drive it without breaking down too often! These cars were meant to be driven.

[Lil Teezy]

Kudos to you and thanks! As a relatively young T fan (at53) I can’t help but wonder how much longer we’ll see these cars on the road as information and experience are slipping away from us at an alarming rate. This kind of enthusiasm for thankless, time consuming, non-lucrative work cannot be praised enough. I decided way back, half way through high school that engineering was not sexy enough for me and focused on art and design (well, of course I’m terrible at math too) so it’s a good thing there’s down to earth folks channeling their energies into filling these voids.
I’m currently operating my T with no starter or generator as they were the first and most obvious roadblocks to just driving the car at all and I’m just not a patient guy. As integral and important as both components may be the replacement costs for these items can be prohibitive, to say the least. Not that anyone is overcharging to rebuild them, or you shouldn’t hire experts to handle things, it’s just a sizeable chunk of change to throw at a hobby. I really think with affordable rebuild kits available, that only require hobby level skills, more and more owners will be able to refurbish their cars to the correct and original running condition we all love to see. This in turn will make it easier to keep cars on the road and make them more understandable and accessible for new or future enthusiasts.
Thanks again to any and all craftsmen who design and produce replacement parts help to keep our history relevant into the future!
-Chris, in Boulder.

[John Codman]

Thank you!
As to Steve's comment about bolts - If my goal was a 100 point Pebble Beach car I would agree with him. That is not my goal, and as long as the bolt head is square where it is supposed to be square, and no Philips screws, close enough.

[AdminJeff]

and no Philips screws, close enough.

ok, on this I absolutely HAVE to agree! I've seen many model T's w/ Phillips head screws in various places and it's just not right! Its like putting peanut butter on a filet mignon.

I can’t help but wonder how much longer we’ll see these cars on the road as information and experience are slipping away from us at an alarming rate.

Hence why all my sources AND methods are stored with 2 other T enthusiasts I trust. When I'm gone, all the parts and products I produce will not be lost. I wish others would adopt this basic and preservationist mentality. It would save the rest of us from having to reinvent the wheel and further the enjoyment of the hobby for many generations to come.

Jeff

[Original Smith]

I think Steve should have a look at the bolts Lang's is selling. I've been buying up originals for years, and was even able to build a car from scratch using all the correct nuts and bolts. It's always been important to me to do this.

[John kuehn]

I don’t think Steve was saying that making exact reproductions of nuts, bolt and other fasteners is a have to do for a Model T. Steve is right to give advice about how to fabricate modern bolts that closely look like the originals. I’ve done that as well as others to complete a car. Exact duplicate fasteners aren’t necessary for a good running car like a generator and starter is. For me an original generator and starter is more important than a fastner but that’s just me.
I did buy a box full of nuts and bolts though from a guy who had dismantled T engines over time that’s helped me in my own engine rebuilds.
There more than a few T parts that will need to be reproduced because of lack of available parts and I hope that others will pick up the task for future T folks.

[jab35]

I admire all aspects of Jeff's work, especially the zinc castings. After reading the article on ignition switches in the Vintage Ford, I do wish someone would do the same with the switch castings, using the original Ford/Briggs specs. Just wishing. Thanks, Jeff

[Allan]

We are fortunate to have dealers/manufacturers who make parts available for us. They deserve our continued support.

I can sympathise with those who like to keep things as original as possible. The parts reproduced are not likely to have been made in the same way as the originals, and so will differ in appearance, but hopefully remain usable.

As an example, Lang's list loose lugs and associated wheel nuts for early demountable wheels. These days they are made by CNC machines and every one is a perfect clone of the next. The nut hex is identical, the built in washer is perfect, the loose lugs are a perfect match with crisp edges and accurate dimensions. A perfectionist will eschew both, in favour of imperfect shear cut lugs and die forged nuts with slightly tapered faces to the washer and even slightly off centre holes and threads.

How you like your car will determine which way you approach your restoration/maintenance.

Allan from down under.