TC Handbrake Assembly Installation

[steve c]

Hi All,
Restoration of TC0894 is making progress and I’ve just completed the restoration of the handbrake cross shaft assembly.
This query relates to the handbrake assembly installation, which I assumed would be plain sailing?
For information my early numbered chassis was straightened and repaired by a specialist along with the addition of ‘birds mouth’ finishers welded into the ends of the chassis boxing to avoid the chassis cracking that can occur on early chassis with abrupt finishing at that location.
Without the ‘birds mouth’ finishers there would probably be no assembly issues but having bolted everything back to the chassis unforeseen problems have raised their head.

Q1) The position of the cable centres are not symmetrical within the chassis?
Measurements from inside the vertical web of the chassis rails to the cable centrelines are 34mm LH and 43mm RH.
Also the measurement from inner edge of LH chassis rail lip to mounting face of chassis plate where to handbrake bolts to is 175mm.
I have a spare chassis from TC4429 as well and this dimension measures 180mm.
However, if I can adjust the mounting face 175mm dimension to become 180mm this would centralise everything.
I’ve never seen a working assembly, added to which my chassis of TC4429 seems to exhibit similar traits. so are the above differences normal?
How well is the chassis / handbrake mounting plate welded to its cross rail?
Could this easily be coaxed into moving or should the plate be bent a little to adjust everything measured above?

Q2) I’m also not sure how close a ‘birds mouth’ should finish in relation to the handbrake assembly?
I’ve just made a small adjustment to the LH ‘birds mouth’ length because with levers set vertical as per Sherrell page 108 and then moving to the maximum possible ‘ratchet on’ position the LH cable attachment was fouling the end of the ‘birds mouth’.
This has been cured but a clearance between brass cable adjusters and the extended inner boxing will be non-existent on the LH side at present with the offset described above?
In operation on the road will the ratchet ever be at the maximum possible on position?
Lots of words, which I hope make sense but does anyone have any advise they can offer?

Best regards,

Steve TC0894

[Tim Jackson]

Steve,
Here’s a photo of my handbrake assembly setup, where it connects to the chassis. The lever needs adjustment (more vertical), but it works fine. Hope that helps. Tim

[steve c]

Hi Tim,
Great photo, just what I needed to see.
Will be making a few adjustments to my birds mouth webs this weekend.
Thanks for giving your time to reply.

Best regards,

Steve