Restoring a 1-3/4 HP Monarch - Part 2

Reclaiming its crown

| June/July 2010

  • monarch 1
    The Monarch’s broken governor weight.
    Photo by Peter Rooke
  • monarch 3
    The governor weight after brazing and addition of the strengthening rod.
    Photo by Peter Rooke
  • monarch 4
    Completed repair to the governor weight.
    Photo by Peter Rooke
  • monarch 2
    The governor weight after brazing, drilling it for the support rod.
    Photo by Peter Rooke
  • monarch 7
    Inside the magneto after removing the front plate.
    Photo by Peter Rooke
  • monarch 8
    The cracked top cover.
    Photo by Peter Rooke
  • monarch 6
    The magneto as removed from the engine.
    Photo by Peter Rooke
  • monarch 10
    Cutting the slot in the electrode.
    Photo by Peter Rooke
  • monarch 9
    The bent electrode.
    Photo by Peter Rooke
  • monarch 11
    Movable electrode after cutting the taper, ready for brazing.
    Photo by Peter Rooke
  • monarch 13
    Speed lever with new spring before assembly.
    Photo by Peter Rooke
  • monarch 15
    The assembled magneto and igniter.
    Photo by Peter Rooke
  • monarch 12
    Magneto trip finger showing the wear before it was squared off.
    Photo by Peter Rooke
  • monarch 14
    The old and new roller.
    Photo by Peter Rooke
  • monarch 16
    The first cut of the cast iron on the band saw.
    Photo by Peter Rooke
  • monarch 17
    Cast iron block with the corners sawn, marked out ready to mount in the 4-jaw chuck.
    Photo by Peter Rooke
  • monarch 18
    The muffler interior bored out prior to cutting the thread.
    Photo by Peter Rooke
  • monarch 19
    The front plate after brazing profiled section.
    Photo by Peter Rooke
  • monarch 20
    Using the mill and rotary table to mill the edges of the front plate.
    Photo by Peter Rooke
  • monarch 21
    Completed muffler front plate.
    Photo by Peter Rooke
  • monarch 22
    Ready to braze the bolt supports. Note the recesses cut for the lugs.
    Photo by Peter Rooke
  • monarch 23
    The finished muffler.
    Photo by Peter Rooke

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The following is Part 2 of a three-part series documenting Peter Rooke’s restoration of a 1-3/4 HP Monarch badged by Nelson Bros.  Read Part 1 here .  

Governor weight
One of the governor weights had broken off in transit, splitting not far from the pivot hole. While it was possible to cast one using the unbroken governor weight as a pattern, this was not something that I could do myself. Before considering casting an attempt was made to try and repair the weight.

Both sides of the break were given a good cleaning with a brass brush and were then coated in soldering flux before heating to brazing temperature to draw out all the dirt. Despite being a recent and clean break it was amazing the amount of dirt that came out of the casting, which turned the flux black.

When the pieces had cooled, the flux and dirt were wire brushed off, also using a sharp pointed cutter in the Dremel to clean out the crevices. Again, both pieces were coated in flux and the process repeated until the flux retained a degree of its original color on heating. Then it was time to braze the two pieces together.



After cleaning and fluxing the two pieces, they were wedged in the correct position on the brazing hearth. In order to avoid overheating the thinner section and destroying the properties of the flux, heat was first applied to the section by the body of the weight then, when at brazing temperature, the flame was moved up to the other parts of the repair. Once the braze had flowed and the repair made, the weight was covered with fire bricks and allowed to cool slowly to stop the iron from becoming brittle.

To support and strengthen the repair, a hole was drilled lengthways through the area of the break so that a 0.125-inch steel rod could be inserted. The area around the rod was cleaned and the rod covered in flux before it was pushed into the hole. The weight was supported then heated once more, and braze touched to the rod so the rod was firmly soldered along its length. Again, it was allowed to cool under the warm fire bricks.



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