Fuller Engineering Services

11/06/2026

Reliable Repower Released!

Early 90's Les Allen Repowered from Lister LPW4 to Perkins HD46.

Initial Evaluations revealed a failed Lister LPW4 with a disturbing history of incomplete prior work, wrong oil supplied by a service engineer and multiple overheating events. Despite the best efforts of the owners to care for this engine and fit new parts as needed, it was soon decided that replacement was the preferred option for a reliable quality outcome.

Attempts to find a good condition LPW4 revealed limited options and furthermore our misgivings about the design and overall robustness of these engines was growing.

We sourced and supplied a good condition Perkins 3.152 (HD46) with a PRM gearbox which was rigid mounted into the boat (solid engineering with no mounts to fail). This provided a significantly a more robust engine whilst also being era appropriate for the early 90's build of the boat.

To achieve fitment the existing CV joint and thrust plate were cut out and set back to allow the new engine to be sited within the profile of the existing beds. Careful measurement was needed to ensure that the engine fitted first time, as clearances were limited but not impossible. The majority interests being to ensure that the engine had good access for servicing and to reduce labour costs through careful design planning.

Other work included a new skin tank for cooling and fuel tank access for diesel bug removal. Converting from raw water to skin tank cooling significantly reduces the chance of failure from blocked inlets, failed pumps and generally brings the boat into line with conventional practice. A large tank was fabricated on the Starboard side with a generous compliment of baffles and vent points at each end.

Coolant circuits were ported and plumbed with 1.5" hose and the system runs at ambient pressure to remove another common failure point sometimes seen in pressurised systems which can cause skin tanks to air lock if issues develop.

Overall the boat is in excellent shape with a very sound hull and pleasing lines. I really hope Bob and John Allen would approve of the upgraded equipment!

Very happy to help out the owners with a quality and stress free future. We always aim for reliable engineering solutions matched to the boat and intended usage.

03/06/2026

Recent Repower - NB Birmingham. Alongside other works, I have repowered Birmingham from Lister HB2 to Lister HR2. A new final drive ratio of 2:1 achieves a suitable matching for the existing propeller, ensuring correct loading of the engine and preventing a wet exhaust from developing. Birmingham's old engine will be fully rebuilt and available for a trad / historic repower when completed. Also some new electrics as part of a larger upgrade system on butty boat Barnes. All engineering works arranged and undertaken in person at Lime Kiln Basin, Stone.

06/03/2026

This is why you never trust AI.

Diesel engine internal part 😱🚂🚒👍🙏

26/02/2026

30/11/2024

Keep Your Cool!

Adjustments to belt tension on a pair of BMC Captains in a river cruiser. The raw waterpumps were cantilevered at considerable radius off brackets that lacked strength and flexed. The wrap around on the pulleys was also limited. Doing my best with not the best!

Recommended some upgrades, but this was supposed to be a holiday, so I left it there!

Mid Heatwave in 2018.

18/11/2024

Something Different!

I enjoy new challenges in engineering. Here we see my first attempt at structural steelwork in the form of a 6m x 6m steel outbuilding.

I designed this building in partnership with the customer, which was based on the form and features found in a wartime codebreaking hut from Bletchley park.

I decided to get the pens out and developed the kit of parts manually using engineering drawing skills learned at school.

Detailed drawings were prepared to show the mitre angles for cutting the RSJ and Channel sections. The steel delivery was dropped off as a pack of pre-cut parts which I then fabricated on site into the final form. Thankfully the supplier was reasonably accurate and only one or two sections required minor modification.

Bracing and joining plates were created manually from 8mm (5/16"!) plate in the workshop. We did use metric bolts, but I guess we could still upgrade to imperial if we wanted 😋.

I erected the building in person, more or less unassisted with only a scaffold tower for support whilst working at height. The tree did lend an occasional hand, but the majority of sections were lifted and positioned using manual methods. With the right strategy heavy items can be handled with relative ease and efficiency.
Not a back breaking job!

I like to ensure accurate geometry and proper alignment in my work. A solid foundation was provided by the customer in the form of a compacted MOT Type 1 sub base. I created the base frame ensuring truth with basic trigonometry and a level. Ongoing checks ensured that the accuracy was not lost as the job progressed.

My design tolerance was +/- 2mm, with a maximum allowable deviation of 5mm on major dimensions. This was more as a personal challenge than anything. I think i got it all true to a maximum error of 1/8" which was seen only once or twice. It was more or less good to 1/16th" on average.

A fantastic and enjoyable project which was capably completed by the customer and is enjoying mixed usage across various themes.

17/11/2024

Here's a very typical one from the Dragons Den - A Lister HR2M which I attended due to poor running, excess smoke and oil bypass (oily exhaust).

The owner had been supplied the engine in good faith and had installed it into her newly built bespoke boat. Having experienced some issues with smoke and a wet exhaust, the supplier advised that it may be due to bore glazing and that a proprietary "glaze busting" solution should be added to the fuel. After admission of this fluid, oil bypass increased significantly, leading to a speckled cabin with runs.

The next suggestion was that the injectors may need looking at. This is a typical excuse for wet exhaust. Injectors are easily removed and potentially improved - perhaps appeasing a customer who is less than satisfied. The supplier decided not to attend to the engine in person. Such "Mobile" engineers would perhaps be better finding a job with BT or another telecoms provider - clearly they can fix problems over the phone!

I undertook a full top end rebuild of the engine in-situ for the owner. It was very clear that the engine had been "built" (thrown together) from an assortment of worn out parts pulled from several different engines. Of course it had a generous coat of green paint applied in true dragon style!

I later specified and upgraded the propeller to give the engine a proper loading and improve the boats performance.

Another one Sorted! 😀

15/11/2024

Factory Fit!

I will always recommend a Low Hours Factory Built unit over a rebuilt engine. Whilst rebuilds are feasible and I do undertake them, it is generally more cost effective to find a low hours industrial engine and adapt it for marine use.

Factory built engines benefit from quality inspection at every stage and parts will have been created to an optimal tolerance. Materials and processes were generally of higher quality than is seen with many aftermarket parts found in rebuilds.

This HR3 was rebuilt by Lister Petter and then stored.
I recommissioned the engine which was then installed by the new owner into Fuel Boat Bargus.

The engine has done fine service in a commercial roll for many years.

15/11/2024

Don't Loose Your Drive!

Emergency repairs to a drive shaft removed from MB Tench in 2014.
I believe it is still going strong after just over a decade!

My work does not stop the engine. I look at the whole system of power transfer to the propeller and can advise on any emerging issues or improvements.

If you are stuck and I can get to you I will do what I can to help. 😊