Restoration of Canadian Scout Car Ford Lynx I, Mk.III No.1726

[lynx42]

The bulkhead between the engine compartment and the crew consists of two metal panels with ¾ inch plywood sandwiched between them.

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Crew cab side.

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Engine bay side.

Both metal panels were badly rusted and had to be replicated. First I had to remove all the fittings including the choke and hand throttle cables as well as the rubber grommets and numerous other small things.

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The plywood between the two metal plates was completely shot and was only good for a fire starter.

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A sheet metal shop in Bairnsdale cut out the shapes and I drilled all the holes. There is an inner and an outer as well as a small removable cover to get to the gearbox. Fortunately for me, the rust was no where the holes were and I was able to use each old panels as a template for the new ones. All the holes were able to be positioned correctly and the end product was very satisfactory. (I don't think I have photos of them as supplied from the sheet metal shop.)

Rick.

[lynx42]

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Rubber grommets are a bit past it.

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I searched the web for new ones but was unsuccessful so what to use to replace them?

I have for years picked up all sorts of rubber suspension rubbers and the like. So I dug them out and found that I had a few rubbers which I drilled to size inside and then shaped the outside, I then cut them not in half but about 1/3rd of the width which gave me two thick and two thin half grommets. Using the two thick ones, I trimmed them to size and then when I was ready to fit them I glued the two insides together which resulted in an excellent grommet looking from both sides and fully insulating as well.

Rick

[lynx42]

Plenty of rust.

Rusted inside of the panel.

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and the outside as well.

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The choke and hand throttle cables were rusted solid in their Bowden conduit.

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Every panel, fitting, cable, in fact every single thing, is grounded with earth straps. Here the earth straps are attached with Bolted on fittings to the two cables.

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Rick

[lynx42]

Part of the fun is getting things apart. The hydraulics were not that, not fun. With nine units all connected to the one reservoir there were the hydraulic lines going every where. (see post #15)

There is a clutch pump and slave cylinder, a brake master cylinder and four wheel cylinders, an accelerator pump and a carburettor slave cylinder to be disassembled and re-kitted and or re-sleeved

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The clutch master cylinder.

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The clutch slave cylinder.

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Slave cylinder starting to come apart.

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I was very lucky to have a spare slave cylinder as not all things come apart the way they should.

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In June 2013 I took all of the hydraulic items to ‘The Brake Place’, in Berwick. Andy Seymour undertook the refurbishment of the 4 wheel cylinders, the master cylinder, the clutch pump and slave, and the hydraulic accelerator pump. The accelerator slave cylinder was a new old stock item I picked up many years ago at one of the Corowa Swim-In auctions supplied by Alan Newton from SA who was a Lynx owner but did not recognize the slave cylinder. Lucky me.

Rick.

[lynx42]

The clutch master cylinder did not look much but it did come apart without too much trouble.

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I cannot say the same about the slave cylinder. Thank heavens I had a spare and was able to recover the housing from the spare and the workings from this one.

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The master cylinder had been lying out in the weather for 57 years and came apart eventually with out being harmed.

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Rick.

[lynx42]

This is the accelerator pump. The pedal has a rod which comes through the floor and attaches to the bronze lever.

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Andy Seymour did a great job including the re-sleeving of the bore with stainless steel and re-kitting it.

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Rick.

[lynx42]

The accelerator pump slave cylinder was in a pretty bad way but as I said earlier, I had purchased a new old stock one at a Corowa Swim-In auction.

There is a thick rubber hose connecting the slave cylinder to the supply pipe. This is to allow for engine vibrations which if it was solid, could work harden and fracture the supply pipe. The slave cylinder bracket bolts onto two of the manifold studs. I had two different types of brackets so I think the now unused one is from either a later or an earlier Lynx.

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What a beauty. It still had the hydraulic oil inside 70 years later as I found out the hard way when it sprayed all down my front.

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An interesting brass notice still attached after all these saying to use Brake Fluid only.

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The thick rubber pipe was still attached to the new pump and in brand new condition.

Rick