The RELIANT TW9
or the story of three different identities!
 By Mick  Leak

Part 2

Click to access Part 1

Having looked at the history of Reliant and the predecessors of the TW9, its time to move on forty years and look at how I set about making something useful out of a 37 years old vehicle that had already lived two lives. From a Road Sweeper to an artic! Whilst the changes might seem like the product of an enthusiast, in reality, BTB Engineering converted many ex-municipal TW9s and Ants into something else – like pick-ups, tippers and milk floats – such was the longevity of the individual vehicles.

I had seen the Ants on television when they were first shown to the media but to be truthful, I didn’t give them much of a second thought. However, I became interested when I used to pass not one, but two, in a garden near where we used to live. What seemed remarkable to me was that the chap was converting them into tractor units to haul trailers. I did not know at that time that the concept had been tried before but I was fascinated with their progress.

Time moved on and so did I. I had forgotten about the TW9’s and it was the furthest thing from my thoughts when I was invited to a transport rally at the Shipley Glen Tramway, West Yorkshire. It was my first visit to England for nearly three years so it was a whirlwind-like tour of relatives, friends and places. Vince Kitson, who had purchased our house, had extended the invitation and when we met up he told me he had acquired an Ant and it was at the Keighley Bus Museum’s premises.

I managed to squeeze in a couple of hours on the Monday evening to take a look at it. I realised there was quite a lot of work to do as Vince explained what he would like to do with it. Basically he wanted to build a trailer that looked like it was a haulier’s truck but fitted out internally as a camper van! As we postulated on the best way to go about this, he asked if I would restore it in Ireland. I eventually declined the request because of practical difficulties and heard no more about it.

However, having tried to get the vehicle’s engine running and failed, Vince was beginning to realise that it might not be suitable for his needs and he began to look for something else more suitable. Meanwhile, the vehicle was taking up space at the Bus Museum and also costing money in storage fees. In April 2007, Vince asked if I wanted it! He would give me it and even arrange for the transportation to our cottage if I would take it. Without any strings attached, I said yes.

It took over seven months for it all to come to fruition (but it did!).  Mid November saw me eject the car from the garage and my brother and I shoved the Reliant in. At that moment I wasn’t aware of all that needed to be done but Martin reckoned that the engine was complete and we could have the aluminium head skimmed, the cylinders rebored, new pistons, etc, etc. In the end it did not these precision machining jobs but it did need a lot of time and effort in determining why the engine would not run properly.

The first real hurdle came with brakes (there were none!).  No brake parts came across with the vehicle. It took a few weeks to track down the correct type and I am grateful to Power Track in England. It turns out that the rear cylinders were originally fitted to Austin Somerset’s in the ‘fifties - whilst the front cylinders were of early Hillman Imp type!  However, after I had ordered the back brake cylinders, I decided to jack up the front end of the vehicle. As the ‘Ant’ just fits in my little garage, I did not fancy working in the rain so the activity had to await a dry day. Imagine my horror when I found that there were actually no brake parts whatsoever on the front wheel (or anywhere else as it turns out!). Apparently, when a new King pin had been fitted, the front wheel had been refitted and all the parts left in a cardboard box (which might still exist somewhere in Bradford).

Without front brakes, the vehicle could not be driven on the road and I was left with the feeling that my troubles were about to begin. I knew that Power Track had the correct cylinders but nothing else. I phoned the owner, Paul Hobson, to ask him to include the front cylinders in my order and also told him of my plight. He promised to ring back if he could identify the type of brake shoe that Reliant had used. True to his word, he found that between 1968 and 1970, Ford had fitted them to their Escort MK1 vans and certain Estate cars. He regretted that he couldn’t supply the shoes but I will always be grateful for pointing the way ahead. I bid for a set of Ford rear shoes on eBay and, being intended for a four-wheeler, I ended up with a spare pair for future use!


Left: BTB Engineering of Blackburn offered all possible vehicle types available including this articulated low-loader fitted with vacuum brakes and connected by a proper Fifth wheel
Having acquired brake shoes and cylinders, it was time to look around for the little bits like springs and pipe nuts. Modern stuff is metric so it was back to England, this time to a Reliant dealer for some more bits. My brother supplied some springs to pull the shoes together and I raided my model spares to make springs for the retaining pins. Martin also supplied and made the front brake pipe as well as remaking the existing rear cross pipe. Master cylinders were seized but again Martin’s experience and skill sorted them out.

With the brakes and clutch now working correctly, we just needed to get the engine running for a road test. There were numerous little things wrong including the wrong carburettor but again Martin delivered the goods with the correct type of carburettor. After replacing pipes, points, plugs, distributor top, leads etc, the engine ran. It produced quite a smoky exhaust leading me to think that oil might be getting in down the valve stems so I sent off for a full de-coke set. We tried the vehicle out and the brakes worked fine but the engine still gave cause for concern. I was resigning myself to taking the head off but then I had second thoughts about the fuel tank. There was plenty of petrol in the tank but something didn’t seem right. We decided that maybe the petrol was life-expired or contaminated. I decided to take the tank off to clean it. Pressure washing revealed severe corrosion and the signs of the metal being perforated.
The tank, of rectangular construction, was certainly not original and I did not expect to get anything suitable out here in the wilds of the west. I tried to repair it by drilling out the hole and putting a suitably washered nut and bolt in. You try putting a bolt in at the opposite end of a tank from the filler neck. I tied some fishing line to the bolt (after putting the washer on first) then tied a loop on the line and dangled the end into the tank whilst at the same time manipulating a piece of wire through the enlarged hole to hook the line. Once the line was through I gently pulled the bolt towards the hole and pulled the shank through. I used a longish bolt for the job so I could hold the threaded part with a pair of pliers to allow me to put a washer and nut on before removing the fishing line. Then using the pliers and a spanner I tightened it up. I must have applied two much effort to the spanner because I reckoned it deformed the washer allowing it to still leak!

Having looked at all my options, I decided I might have a go at fabricating a new one. On another related matter, I was at our local builder’s provider when I espied a gas cylinder with its valve missing. It turned out it was an advertising display and a sign had originally been screwed in the top of the cylinder. I begged the bottle and took it back home.

After cutting off the base rim, handles and pressure test i.d. plate I had a cylinder with two domed ends. I begged (again) a piece of 2 inch pipe from a firm in Ballina and cut it to size to make the filler neck. I used the cap off the old tank and turned a collar on the tube so the cap would lock in position. Using a hole-saw borrowed from Martin, I cut two holes in the cylinder – one for the filler and the other for sender unit float switch and outlet pipe. Being on a radius I had to weld a washer on and drill and tap it for the sender unit. A gasket was made from an old cork floor tile! I then fabricated a pair of carrier brackets and took the rightangle out of the stainless steel strapping that had formerly held the other tank in place.

The newly lengthened chassis showing the plate where the tow ball had been fixed and also the new petrol tank.
So, the new tank with new petrol, a few tweaks of the engine (by Adrian, our youngest son) and away it went. Martin had eliminated all the other problems and it starts first time now and, apart from the current lack of sound-deadening material (being in the cab is akin to being in a weaving shed), runs well.

After the end of the show season, the model railway was backed into the hayshed and my thoughts turned as to what I was going to do with the truncated chassis. It had been cut off behind the rear spring hangers and needed to be restored to its original length. I required metal to form two new channel sections but I didn’t fancy the idea of a 50 mile round trip to the steel stockholders – nor did I need the 28 square feet of sheet metal that would be left over! After pondering for a couple of days, I took a look at the old petrol tank which had been stood in the open for nearly three months. It was very sturdy and the right thickness to manufacture the channel sections from. Extra-thin cutting discs soon made short work of the tank and a big hammer helped me form the channel sections. Next I cut the rear cross member off to allow the existing chassis to be squared at the ends so the new sections could be welded into position. Once this was done the rear cross member was welded on to the new extremities and all was looking good.

After completing the chassis, attention was turned to the cab which had suffered a number of minor accidents over the last few decades. You have to be careful how hard you rub down the paint but at last I got it to a state where it was ready for painting. I brushed on the undercoat, rubbed that down (or so I thought) and then, masking everything possible, I spray painted the cab. Probably the last time I spray painted was nearly forty years ago - when I refurbished a wheel mounted Vicon-Lely Hay Turner - and you had to stand back some distance to appreciate the new coat of paint.

All I can say is that it is amazing how far insects can travel on a wet paint surface before they become bonded to your handiwork!


The TW9 on the 20th July, 2008 – its only rally outing of the year.
Within a few weeks I would begin restoring the chassis back to its original length.   Photo: Martin Leak
With the cab and chassis repainted and looking tidy it was time to have a go at building the body. For the floor to clear the mudguards, I need some deep timbers and ended up using 6 x 2 rough sawn which I planed and sanded smooth.

The timbers were cut to shape and chamfered using a router before being returned to the workshop for painting. Once dry they were fixed to chassis ready to receive the body framework once I had constructed it. I had decided on rigid sides with a hinged tailgate and also a ladder rack just in case I ever needed to carry anything long on it. The metalwork consisted mainly of 40mm angle and some 50mm for the rear and corner posts. These were all bought in Ballina as 20 ft lengths and brought home using the car and trailer. All were cut to the required length with an angle grinder.
The framework was welded up outside (virtually all the work is, or was, done outside). The headboard had to be fitted in place and painted because this would be hard to reach once the frame was fixed in position against the cab.

Ready for spraying – the bumper had to stay because it was welded on to the chassis!


Right: Getting there! With the body panels fitted they needed priming and undercoating. The inside has been left grey whilst the outside was painted in the same colour as the cab.
Eventually everything was ready for transferring onto the chassis. Bit by bit, I moved the trestles and the framework to one side so that I could park the Reliant alongside and slide everything over. Once in position, the frame was fixed to the timbers and then the sides were clad first, followed by the floor – the latter wedging everything in place.

I had to use exterior hardwood ply because I could not get hold of any suitable hardwood planks of the right size (and price). I decided I would use slotted screws - although Phillips cross-heads were in use in 1972 alongside the former. Screwing in by hand really tested the muscles as I was so used to driving screws in with the battery drill!

The tailgate was the last part of the bodywork and this was welded up outside before being transferred inside for the plywood to be fitted and receive three coats of paint. Once the paint was dry, the tailboard was fitted on the hinge pins and the TW9 was – to all intents and purposes – complete. However, the body needs a further rub down and another coat of paint - plus all the ‘unseen’ parts need a final coat too. I am still undecided whether or not to letter it (I had the Ox Mountain Model Railway in mind) and I will mull this over during the winter months.

I would like to fit a pair of chrome hub caps to the rear wheels as per original spec and, also, possibly acquire a spare wheel to complete it. The cab needs finishing off internally and I need to sound-proof the engine compartment. Hopefully the truck will last many years in its present form and I can concentrate on model making and the model railway!

The vehicle is now tidy and presentable as a “working” vehicle and is not restored to concourse condition. For those who wish to see their face in the paintwork, sorry, you’ll have to use the mirrors! I doubt that I have either the patience or capability these days but I do look forward to our Club’s Road Runs – at least I now have something to join in with! Oh, and one other point – when the vehicle was made into an artic in the early 1980’s, it was used commercially to gain access (being only five feet wide) to warehouses and other difficult places where its’ full-size cousins could not!

A special thank you to my brother, Martin Leak, without whose considerable knowledge and help I would have come unstuck with the engine and brakes (not forgetting the electrics too)!

Mick Leak

 

 The (nearly) finished truck. It just fits in the garage – there being only 40mm to spare! The car has slept outside for the past year and may do so for the remainder of its sojourn with us.


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