First post of the year
Ugh what an uphill battle this was. Bought a new rocker shaft from Small Ford Spares (105E-6563-B) but that turned out to be the "motor sport" version and came with no E-clips for the ends. Also a smidge undersized and with light surface rust at places. Probably same as sold by Burtons.
Next I remembered that I had a stack of old shafts squared away but those were also a bit too worn, though one was almost good enough but had been incorrectly removed so was a bit bananed.
So off to Ebay.. Got a NOS one (2733E-6363-A, 1433716) that also came with some light surface rust at places, nothing that really matters but still.. Polished and thoroughly cleaned that and finally got around to assemble all the bits I had cleaned in preparation in the ultrasonic bath. Clearance spec for the rockers are (as far as I can tell) .003" to 0.055" but luckily these seem to be harder than the shaft so I managed to put together a decent set.
I really did not want to scratch my shiny new rocker shaft so I warmed up the aluminium post in a toaster oven before assembly;
This really did help. Only twice I managed to get the rockers on in the wrong orientation.. New cotter pins were fitted at the ends.
And the finished product;
Usable No excessive play in the rockers, everything moves as a machined part should. Bolts fit through the posts easily but these will need to be tapped to their right places when assembled to the cylinder head. Not be a big deal. Assembly was well oiled, shrinkwrapped & squirreled away for safekeeping.
All this happened in small ~1hr sessions throughout the winter, maybe as the weather warms up I can spend a bit more time at the garage. What's next? No idea but loads more left to do.