1964 Alvis Stalwart

[LewG]

So, where to start?
Those of you that have been reading my Ferret thread will know most of the story up to now but for those that don't, here it is.
As a 9 year old into all sorts of old vehicles and trying to fix anything I could (usually making it worse) I went to school in a nearby village, taking the bus there every day. Parked just off the road in a farmer's field was this big old boat like 6 wheeled military lorry, so with a keen eye for military vehicles I set about finding out what it was and all about it. I hated going to this particular school and was getting bullied and struggling with work, the usual, so in a weird way driving past this poor old machine thinking that one day I'd save it and give it a better home was sort of a small motivation to make it through the day and carry on. On a couple of occasions I had climbed in the back for a closer look and managed to take a few photos. This one is approximately 2003, taken by a 10 year old me.
20170504_233607 by Lew Garner
I managed to twist Dad's arm and we approached the owner on a few occasions about buying it but it was never for sale. He lived in a lock keeper's cottage in the middle of nowhere as a bit of a recluse, and allegedly years ago used to actually sail the Stalwart back to the house!
Anyway around 11 years ago the 'Stolly' disappeared from the farm and that was that. The farmer wanted rid of it and urged the owner to sell. Nothing happened so he took it upon himself to get rid and it was sold to a military dealer, who allegedly arrived with a low loader and managed to get it running out of a petrol can with new batteries, ticking over like a Swiss watch after God knows how many years out in the elements.
Anyway idly browsing through one of the military vehicle sales websites recently as any sane person does, I spotted four Stalwart Mk1s for sale and thought I'd click on the ad just out of interest. Reading through, hold on... that reg number sounds familiar. I checked back on my photo and sure enough, there she was. I'd found 'my' Stolly
20170506_110548 by Lew Garner
20170506_113216 by Lew Garner
It was probably a given from there but I arranged a visit and had some help from Trevor the owner, who is now looking to retire and move to France. He and his son Neil helped in removing the sun gears from the planetary hubs as the driveline is stuck at present, we believe due to a transfer box issue. We eventually come to a deal and a date was set for delivery, that being today!

So a brief bit about the Stalwart in general, it was designed in the late 50s primarily for a Cold War scenario, designed to carry ammunition and fuel alongside main battle tanks over pretty much any terrain. They are also amphibious as it was foreseen that it would need to cross rivers/lakes etc in the field. They have a payload of 5 tons and use two PTO driven Dowty water jets to push it through the water at a speed of around 6 knots. It is a Rolls Royce B81 straight eight petrol engine, twin plate 12 inch clutch powering a 5 speed box with full speeds forward and reverse, the transfer box then transmitting drive through a H pattern with various prop shafts and bevel boxes etc to all six wheels. Notoriously complex and susceptible to 'wind up' as it allows speed differences side to side but not between all three wheels on one side if that makes sense, meaning all three wheels on one side try to rotate at the same speed regardless of whether you're going round a corner. It's a commmon occurrence apparently to see a Stalwart whacking up a kerb to 'unwind' the wheels on each side.

Delivery day
After not a great deal of sleep last night I turned into the yard at 7am and there it was on the trailer.
20170623_073314 by Lew Garner

Having no sun gears in the hubs means basically no brakes so thankfully the lorry trailer had a big winch on letting it come down with a pretty controlled descent. I was on steering duties and nearly wrenched my arms off just trying to keep the thing straight down the ramps, no power steering as dead, 9 tonnes and four steering wheels adds up to a fairly heavy experience.
We then drafted in the little Ferret to pull it back round to its resting place for a while, a task the little beast managed with relative ease!
20170623_081924 by Lew Garner
20170623_082404 by Lew Garner
20170623_083524 by Lew Garner


Really all we've done today is just farted about lubricating hinges and having a good look over her. We took the plugs out, cleaned them and put a good squirt of WD40 down each bore for good measure.
Here you can see both the extent of the work needed and the basic layout of the inner workings
20170623_090245 by Lew Garner
Fuel tank at the front, all 110 gallons of it! The two sliver boxes are the air cleaners.
20170623_090252 by Lew Garner
Engine and water jet ducts at the rear.
20170623_091652 by Lew Garner
20170623_135648 by Lew Garner
Swim controls etc for going in the water, I suspect these wont be needed for a while longer yet!
20170623_135733 by Lew Garner, on Flickr
Here is looking to the right side of the cab, complete with rifle racks
20170623_164459 by Lew Garner, on Flickr
We tried a couple of batteries on it to see if it'd wake up at the dashboard and sure enough it did, even the original 1964 fire protection system lit up when the test button was pressed
20170623_143635 by Lew Garner, on Flickr
Also freed off and lubricated the drop sides

That's all for today, I need a pint!

Edited by LewG on Wednesday 19th July 23:53

[LewG]

Just to add I also managed to track down her history cards, here are the copies. As we can see into service January 1964 and disposed of 1988. A lot of time spent on Germany with BAOR, short for British Army Of the Rhine. At one point it served in the same regiment as my Ferret albeit a few years later.
Screenshot_2017-06-17-10-48-29
Screenshot_2017-06-17-10-47-17

Edited by LewG on Thursday 20th July 00:10

[LewG]

I don't know about that actually, I did wonder myself. I imagine Class 1 is 'dire'
Funnily enough there was talk of this over on the Historic Military Vehicle Forum about making a modification doing just as you say, potentially fitting some sort of dog clutch on the front props to disengage them. I suppose it's a case of whoever is brave enough to put their mind and wallet to it and give it a go. There is one running I believe in the States with a big diesel in and higher ratio transfer gears in the T/box and no front props, they claim a comfy cruise at 55mph!

[LewG]

Thanks all! I think first thing is to assure ourselves that the engine will turn over to start with. After that we can hopefully go for the big fire up.
Turned the master switch on today and tried swinging the start switch but absolutely nothing, not even a clonk. I had a fiddle with some of the wiring behind the dash and managed to lose where I pulled a connector for the ignition switch from so some testing with the meter is required! Daft thing to do but you know how it is when you get over enthusiastic

In the fullness of time I'd like to fully restore her back to immaculate but if we can prove that some of her systems actually still work that'd be a bonus. A vast majority of the work is more related to how long it's sat more than anything. For example the throttle pedal is stuck. The linkage has several rods, clevises and a massively over engineered cross shaft to take the pedal movement from the right hand side of the vehicle over to the left hand where the carburettor is, you can move both ends individually no problem so it's evident the shaft itself is just tight to turn. On the plus side this is easier than a Mk2 Stolly as that's even more complicated with a hydraulically actuated throttle.
Either way I'm very much looking forward to it, I'd love to have a go in a working one like you were so lucky to do Captain S, I've no doubt they are immense to drive.

[LewG]

Cheers for that Aaron, as you say the two sets of points is much the same as the ones on the Ferret, we spoke to Trevor about this and he said in the past he's made up a little gauge to set them to 45 degrees as they should be. Should be an interesting project if nothing else, to hear her fire up again would absolutely make my day

[LewG]

Could not agree more, it is one if the all time greats of British engineering, the level of thought and expertise put into it for the time is incredible. At no point was it a lorry then made to float, it was designed to do exactly all that was asked of it from the very beginning.
Today I've been draining fluids and pretty it ain't! Currently fiddling around with getting the dash panel out. When people say they're not nice to work on they're not lying

[LewG]

Cheers guys, the full Salvage Squad episode with the Stolly is still on YouTube, link here:
https://youtu.be/h8dzEX3pCNE
I remember getting all excited back then and taping it so I had a copy not many 10 year olds you'd get doing that

Strange about the diesel thing, I suppose the easiest option would be on a diesel with more torque just change the gearing inside the power take off box so it drives the impellers at the same speed but lower engine revs.

If anyone is local to Bedfordshire and fancies a look round it and the other junk in the 'collection' they're more than welcome, there's nothing better than showing folk a new toy

[LewG]

Sorry geo missed your post last night, that is stunning! To me definitely the era of the last truly pretty Astons, a lot of them seem a bit over the top and footballer now in my opinion.

[LewG]

As I've said before one of the main aims is to get the engine cranking over but at the moment with master on we're getting instrument lights, but nothing on swinging the starter lever.
I know from my experiences with the Ferret that they have these troublesome plug blocks behind the dash as they're the same universal switchboard. Every wire is either white or brown and has a small yellow tag with writing on to tell you what wire it is. Unfortunately the writing is a lot more faded than it was in 1964 nowadays so a lot of it is a bit of a guessing game!
Took the clocks out for better access as getting the dash out was proving a royal pain in the arse, the rear studs holding it in were spinning but slotted on the ends for a screwdriver to hold them steady whilst you undo the nut. Naturally they were rusted solid and inaccessible with a grinder etc so I soaked them in Plus Gas and tried a different method.
Here is the plug block behind the dash, they are effectively rubber boots that push together with pins either side and make contact, and go pretty crusty over time. Surprising most of the connections were in pretty good condition. I'm waiting on a wiring diagram for the board so that I can see if I'm getting power out of it on the appropriate wire when the starter switch is actuated. At least then it'll give me a clue as to whether it is the switch or not. I do have a spare switchboard in the shed so if this proves to be the case it may be as easy as just swapping them over as they are a right pain to get apart, and more crucially back together!



Before this I cracked off all the fluid drains and let them flow out, the radiator first. I came equipped with the Mapp Gas expecting a battle in getting the plugs out but surprisingly they all came undone easily.

20170624_132006 by Lew Garner

Unfortunately someone appears to have filled the gearbox with Baileys. Much to my disappointment about a pint of water flowed out first. The transfer box wasn't much better!

20170624_131217 by Lew Garner
20170624_131934 by Lew Garner
Engine oil clearly oxidised but not awful, only about 3 litres came out as opposed to the 5 gallons or so that it should have, as the engine is dry sump and the pipes run right from front of the vehicle to the rear I should think there's a lot of it still languishing in there.
Other half came over unexpectedly last night and saw the Stolly for the first time, the look of utter despair on her face was one I will not forget for a long time

On the plus side I remain optimistic
20170624_190252 by Lew Garner

Edited by LewG on Thursday 20th July 00:16

[LewG]

Yep that was the plan mate, a lot easier to see it on a bulb and at least it puts a small draw on it unlike a meter. That's very kind of you, thanks very much. If you're ever back in the UK we're only about 20 miles away from Luton airport, will have beer waiting

[LewG]

As you say eltax any knowledge put forward is always a bonus, the silliest question is the one not asked so it's in the same vein.
Yep this is one of the reasons it's almost 'desirable' if you could ever call it that, all of the swim gear is intact and still there, and for a start it is an early Mark 1. Most were Mk2s as they made about 900 of those as opposed to only around 140 Mk1s, as you can probably see on her history cards she is Chassis 35 of the batch.
Regarding road legality there are several road registered Stollies out there, technically I will need a Class 2 HGV licence to drive it on the road, having passed my test post 1997 I can only drive up to 3.5 tonnes unless the vehicle was manufactured pre-1960, which is what allows me to drive my Ferret on the road as that's 1954 and weighs about 3.7 tonnes. Unfortunately this isn't and there's no getting round that, people have tried in the old days registering them as agricultural vehicles etc and claiming that they only drive them between two pieces of land that they own a short distance away. There are a lot of silly rules and regs out there and they have been done to death on other military vehicle forums, the MV movement as a whole needs an ambassador (or several) to try and talk to the authorities and get us all singing from the same hymn book in order to keep everyone happy and these vehicles safe and legal on the road.
Can't see that working as front and rear are still linked via the prop shafts and centre boxes, whether the centre wheel is touching the ground or not won't really matter. I've heard varying accounts of it really, some say it's fine and they've never had an issue over thousands of miles, others say it's a real issue. The Ferret is much the same design and does get wind up to some degree, I've never really noticed it but just in case when I turn back into the farm yard after a run to a show and back I give it a really good thrash across the potholes and bumps around the paddocks. One time I jacked an entire side up to grease the suspension pins and it was rather unexpected when the wheels shot round on their own!


This explains it very basically

Edited by LewG on Sunday 2nd July 09:59

[LewG]

Regarding spares it's not like a let's go on eBay and find what we need, sometimes things pop up that are a bit unexpected on there but for most specific bits it's go to the specialists or make/mend. There is a chap called Richard Bannister who is superb for parts on these vehicles and in particular the Rolls Royce B-series engine parts like what this has. Another guy we know of who seems to keep himself to himself has entire sheds and hangars absolute chocked to the ceiling full of bits on an old Dorset ex Naval base, it's a bloody amazing and eerie place to walk round but what a gold mine!

[LewG]

They're a great old bus Shaker, I had the pleasure of driving an MJ round a seriously harsh off road course for the day and it was absolutely unstoppable. Just keep thumbs clear of the steering wheel as when hitting ruts it will snap them off! As you might have been able to see in the photos my mate Matt has the older brother parked next to the Stolly, an RL

Edited by LewG on Sunday 2nd July 10:00

[LewG]

Last night's progress was fairly minimal, I filled the gearbox with some red diesel which I'm going to leave to soak for a few weeks. Had a look through the filler and it all looks relatively clean in there which is a pleasant surprise considering what came out.
|https://thumbsnap.com/bP1nQkid[/url]
Then I tried dropping the rear tow hook, it's hinged with a plug behind it. When removed the plug allows access to the crankshaft pulley meaning I can try turning the engine over by hand. Was very stuck and even with heat and a big old steel bar it was putting up a real fight so I just left it soaking in Plus Gas for the night

Edited by LewG on Sunday 2nd July 10:02

[LewG]

Aaron as I said on the email, thanks so very much I really do appreciate you going to the effort of getting hold of those for us.
Funnily enough I've already been asked if I'm starting my own International Rescue may be some time before we get to that stage.
We've got hold of some old curtain sides off of an articulated lorry to put over it whilst it has to live outside, silly levels of rain due later apparently so will head up there this evening and sheet it up. There is new units being built at the farm so hopefully it will be going in a shed eventually

[LewG]

That is surprisingly like it! It's like a hybrid of an FV432 and a Stolly.
Absolutely pissing it down here now so unfortunately that stops play for the evening

[LewG]

Really I can assure you that no, nobody needs to see that!
I managed to lower the tow hook today with some heat and a 12 tonne bottle jack between it and something solid. Worked a treat! I then needed to remove the hex plug, a 1 inch Allen bit. The Ferret has the same plug on for its crank handle hole too but unfortunately Dad broke the tool for removing it several years ago and I haven't seen it since. Rather than mullering it with a chisel etc I decided it'd be easier to drop the entire rear belly plate which wasn't too bad a job at all. About 30 3/8 UNF bolts hold it on and four big buggers in the centre going into a rigid cross beam inside. With this removed I put the Ferret crank handle in and heaved on it. Hooray! She turns

[LewG]

I think I've half worked out what's going on with the Stalwart not cranking over on the starter, it would appear that the ignition junction box on the engine containing two ballast resistors is not getting power from the dashboard electrics. This supplies 24v to the starter solenoid , 12v to the coil under normal running and 24v during cranking as the resistors are bypassed when the starter is actuated. Someone has been fiddling in there and it looks as if they've supplied 24v direct to terminal 'SOL' to get it to turn over in the past, this is what ours looks like


And a better view of the insides on another one

Edited by LewG on Sunday 2nd July 19:19

[LewG]

https://youtu.be/puwdO_JAwjk

I'll just leave this here.....

[LewG]

Apparently you need water around the impeller bearings before activating the jets to lubricate them and keep them cool as they're made of PTFE, quite advanced stuff for the time!
Tried to start her the other night having put sone fuel directly into the carburettor. Not even a cough so on checking for a spark unsurprisingly there was nothing. I cleaned the points this morning and hey presto, a big fat blue spark on turning it over!
20170702_111130 by Lew Garner
As you can see here it uses two sets of points on a four lobed cam making up all 8 cylinders.
The rev limiter is built into the rotor arm and is somewhat conservative!
20170702_110730 by Lew Garner
As I mentioned before the engine is dry sump on this. The engine oil tank is up at the top of the vehicle so over the years the oil has slowly drained back into the engine, there was only a tiny bit on the bottom of the dipstick so I topped it up with some fresh cheapy 5W-30 semi synthetic just enough so that if it pumped all the extra oil back in the tank it wouldn't overflow and start pissing out the tank breather. Having run it oil pressure came up straight away and after stopping the tank was massively overfull with horrible grey oil, definitely worth draining out sooner rather than later and flushing!

Edited by LewG on Thursday 20th July 00:23