The specialist: Bailey Morris Ltd

By Paul Hardiman

| 6 Aug 2024

Classic & Sports Car – The specialist: Bailey Morris Ltd

In a high-tech world, it’s refreshing to see some things going on as they always have.

At Bailey Morris, venerable machines line up like old grey retainers, still earning their living.

Thirty propshafts a day come out of the manufacture and service department, built or repaired and reconditioned in the most traditional way, which includes skill and feel behind tonnes of hydraulic force.

The Bailey Morris Ltd workshop uses traditional machines to make propshafts for classic cars

Riding herd is Brian Presland, who’s been with the company for 27 years and is “passionate about props”.

His favourite machine is the converted Vickers press that is used to straighten shafts after welding has inevitably pulled them slightly out of line.

He demonstrates on a new shaft destined for a Jaguar, gradually fiddling it to a 0.1mm run-out, well within the Bailey Morris tolerance of 0.3mm down the entire length of the shaft (compared with the ‘modern’ tolerance of 0.5mm).

“I love this old machine,” he beams. “It needs a bit of skill. I could do this all day.”

Rebuilding a universal joint is a specialist task

As well as making new shafts – for Moss Jaguar, among others, plus every propshaft that Caterham Cars fits to a Seven – the company will rebuild worn-out or damaged ones, and even create specials.

The universal joints are assembled by hand and feel, using different circlip thicknesses to line up the spiders just so.

“That’s our difference,” says Presland. “We have a range of seven circlips in 0.1mm tolerances for each size of joint.”

Even staked ‘sealed for life’ joints can be rebuilt – though only a couple of times before there is not enough meat left on the yokes to restake them.

Propshaft maker Bailey Morris Ltd has a meticulous and precise eye for detail

Grease nipples can be added for longevity: “Most staked shafts are throwaways – they’re not supposed to be rebuilt, but we can.”

Greasable joints are built only minimally lubricated so as not to upset assembly tolerances, and need to be filled before use.

In manufacture, the main tubes range from 28 to 144mm diameter and are parted-off on an old Ward lathe, then rotary-welded to the joints.

After straightening they are balanced at up to 3000rpm, with weights spot-welded on to ensure smooth running.

Brian Presland completes the final truing of a propshaft after manufacture using an adapted Vickers press

Bailey Morris balances to 12g and under – half the weight of a bag of crisps.

Then it’s into the paint booth – in various colours, and not just black.

Remarkably, the company can turn around a prop in 24 hours, or even while you wait if things are desperate, such as a lorry with an urgent load.

“We can make a propshaft in two hours – painted,” says Presland. “Classic car owners can send propshafts for rebuild by post, or even bring them in.”

Classic car propshafts are available in a choice of colours, not just grey or black

In a corner, Ken Noller plays with various self-adapted chucks and tools on a milling machine and lathes. This is where the one-offs are built.

“Holding stuff is the problem,” he says, “but if I can hold it, I can make it.”

The bespoke yokes and flanges are something Presland is proud of – as he says, “If you can’t find it on eBay we can make it” – but it doesn’t have to be conventional Hooke’s joints; you can have CVJs if you want.

And though the company doesn’t make carbon props, it will balance them.

Classic car owners can send propshafts to Bailey Morris Ltd for a rebuild

Bailey Morris was established in 1977 and took over Propshaft Services, Feltham, in 2007.

It makes propshafts for everything, but the old-car work is now collected under the Heritage & Speed brand, while Extreme calls to the 4x4 and off-road fraternity.

The labels have changed, but the hardware remains the same.

How can you tell a Bailey Morris prop? “Our circlips, phase lines and labels line up and each job has its own unique number [stamped in the fixed-end forging or on the tube] for traceability,” says Presland, proudly.

“That’s how we know if it’s one of ours.”

Images: Max Edleston

The knowledge

Name Bailey Morris Ltd
Address Little End Rd, Eaton Socon, St Neots, Cambridgeshire PE19 8GE
Specialism Propshaft fitting, manufacture and distribution
Staff 35
Prices A typical Jaguar-type propshaft costs between £180 and £250 plus VAT; specials and repairs are individually priced
Tel 01480 216250
Web www.baileymorris.co.uk
Email sales@baileymorris.co.uk