The Sir Nigel Gresley Locomotive Trust LtdSubscribe to 60007

Registered Charity Nº1079591

OVERHAUL 2015 - 2018

All the overhaul photos may be found here.

Sir Nigel Gresley is now out of traffic for overhaul. This will probably take three years and cost about £750,000. If you would like to make a donation towards this overhaul please click on one of the the donate buttons.

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Notes from information supplied by Darrin Crone, Locomotive Engineer.

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From July 2017.

15 August 2017

It is planned for the coach to go to external contractors for overhaul. We use the coach for storage, though not for loco parts which are stored elsewhere. We have already moved some stores back to Grosmont when we transported the axleboxes. The process continued this week when we moved a storage cupboard from the coach to the workshop and filled it with stores. There is still stuff to move and another trip to our Grosmont storage facility looks likely.

We plan to fit the valve liners next week so preparations for this have begun. We have made up some plates to allow the liners to be clamped in place. These fit over the studs in the steam chest castings. There are a number of different types as the outside cylinder stud spacing is different from the middle leading, and that is different from the middle trailing.

The valve liners have an orientation and this is indicated by a groove machined in their outside edge, which must be vertical when finally located. To assist in this small plates have been made that point along the bottom centre line of the steam chest. In addition a tool has been made that locates in the grooves in the liner and allows it to be rotated in to position.

The tender sump was removed this week. Above the sump is fastened a large filter box that prevents solids from entering the feedwater. The last bolts were removed from the sump and it was removed, and this also released the filter. The gasket and silicon sealant sealing the assembly has now all been scraped off.

The leading (gravity) left sandbox was put up this week on new studs. The sandbox came off a lot easier than it went back on as some of the original studs came out with their nuts. To get the sandbox back on a number of studs had to be removed. All are now back in place. A start has been made on fitting the right hand studs but the sandbox will not be put on the loco until the new valve liners are in.

The operating mechanism for the leading sands was put up this week. A new gasket was cut for the left hand sandbox and the fit of the pins in the mechanism is being assessed.

All the fittings from the air brake valves that will be going for contractor overhaul have been removed, and the valves are now ready for delivery to the contractors.

When the leading sandboxes are in place the trailing bogie splashers can be fastened to the loco. This week the spalshers were stripped and inspected. As with many of the thin sectioned parts of the loco they show their age with wear and cracks. One of the splashers was cracked from wear apparently from contact with a leading sandpipe. The crack was welded up and another area of wear rebuilt and dressed. The splashers were given a final clean and have received a coat of primer.

At the rear of the loco frames the damper operating linkage bracket is secured with bolts to the frames. The bolts are wasted so it has been decided to replace them. As this area of the loco has been subject to corrosion this is easier said that done.

Further work has been carried out on routing the cylinder lubricating pipework across the middle slidebar stretcher. Further work has also been done on the airbrake pipework that goes between the ashpan and Cartazzi.

On Saturday the riveting team was assembled again and good progress was made. The remaining front brake cylinder stretcher rivets have been put in. The team then went on to put in the first three rivets in to the spring brackets starting on the left side of the frames. The rivets being specially machined to fit in this location. They went in nice and tight as displayed by the next rivet in the row becoming slack. So this was removed and will have to be replaced.

The trailing bogie wheel splashers are fastened to the loco main frames under the leading sandboxes. They have been repaired this week and are receiving a coat of primer applied by Engineering Team volunteer Anne-Marie Lawn on 10 August 2017.
Photograph: Peter Brackstone.

Trailing bogie wheel splashers

At Llangollen progress continues with the repair of the combustion chamber platework and the completion of the removal of the sling stays. The holes in the firebox roof plate can be seen along with the leading horizontal transverse stay. 10 August 2017
Photograph: Paul Aston.

Llangollen progress

When the new valve liners are put in the steam chests they will be held in place by screws passing through the clamp plates made this week. 12 August 2017
Photograph: Darrin Crone.

The new valve liners

To position the liners accurately they can be turned in the steam chest by the special tool made this week. It is important that their radial position is accurately located so that the gaps in the valve rings run over the bridges between the ports and not over the port openings. 12 August 2017
Photograph: Darrin Crone.

To position the liners

New studs for the right hand leading sandbox trial fitted on 12 August 2017.
Photograph: Darrin Crone.

New studs for a R/H sandbox

The left hand leading sandbox in place. It's a tight squeeze to get the sandbox in between the cylinder casting and slidebar bracket and to get the top through the hole in the footplate. 12 August 2017
Photograph: Darrin Crone.

L/H leading sandbox

The sump from the tender stood on end after removal this week. 12 August 2017
Photograph: Darrin Crone.

The sump from the tender

6 August 2017

The new valve liners were delivered this week to York from Multitech, and the finish is extremely good. They have now been thoroughly inspected by our CME, Richard Swales, who confirms that they are spot on to the drawing. We will now organise fitting.

The tender corridor rear window, the port hole, was removed this week and so was the cover over the top of the vestibule that covers the spring that pushes the corridor connection out. The cover was removed as part of the assessment of the tender condition around the vestibule and the water filler space. Inside the corridor further needle gunning and scraping has been carried out to remove paint and bitumastic coatings in the corners and on the floor.

Work was also carried out under the tender. Now that cleaning has been carried out between the frames it has enabled the various pipe runs and conduit to be marked and a photo survey has been carried out. When this was competed a start has been made on the removal of components that will enable the areas where the tender tank meets the chassis to be viewed and inspected.

The underneath of the front of the tender is crammed with pipework and brake gear and the process of removing this has begun. The water feed valves and associated pipework were removed. The 007 Gang of junior volunteers started the separating of the water valves from the removed pipework. The water feed is taken from a sump and this is in the form of a box which can be removed. We will remove it so that it's condition can be assessed and it will improve air circulation inside the tender. Most of the bolts securing the box have now been removed.

The overhauled cylinder lubricator was returned to York last Saturday and was refitted to the loco this week. After fitting the lubricator the fitting of the pipework running to the front of the loco was begun.

The gravity sandbox studs were refitted to the left side of the frames this week. To enable the sandbox to be refitted, the frames were painted to top coat gloss black on this side.

The bogie centre casting was returned to York this week from machining at contractors. The lower bearing surfaces were polished this week by Engineering Team volunteers. Three of the screws holding the leading bearing plate had come out during machining. Not surprising, as the screws are relatively short so there's not a lot of thread holding them in. New screws were machined and fitted as patch screws. After fitting, the tops of the screws were carefully finished flat with the bearing plate. Two of the screws went across oilways in the plate, so the oilways were re-cut. The centre casting is now ready to be trial fitted to the bogie.

The new plates for the bogie centre casting were welded in place this week. While the welder was with us we also had some welding done to rebuild a small area of wasted plate under the cab.

Work continues around the front of the loco in refurbishing the streamlining securing holes in the footplate angle. All the streamlined screws have been retrieved from store, cleaned and die nutted. Under the centre section of streamlining is the front coupling hook extension casting. This has now been refitted.

Machining began on the first fitted rivets for the spring brackets this week. The hole sizes have been taken and they have been machined to finished size on diameter but the heads and ends are yet to be machined.

The mud hole doors were finish cleaned and descaled this week. They are now ready to be taken to Llangollen for their overhaul to be completed prior to fitting to the boiler.

The leading loco vacuum cylinders were delivered to contractors this week for refurbishment work to their trunnions. There is evidence of some previous attempts to rebuild the trunnions, which will have to be removed before they can be re-sleeved to the BR drawing.

The new valve liners for the middle and right hand valve chest have been delivered to York from contractors this week 2 August 2017.
Photograph: Darrin Crone.

New valve liners

The front coupling hook was refitted to the repainted bufferbeam by 007 Gang junior volunteer Luke Perry. 5 August 2017.
Photograph: Darrin Crone.

Front coupling hook

The left hand water valve with the feed pipe from the tender sump are still connected in this photo. The valve will be separated from the pipework and will be refurbished. 5 August 2017.
Photograph: Darrin Crone.

Left hand water valve

The lower bearing faces on the bogie centre casting have been polished and on this face three new bearing plate securing screws have been fitted, one at the bottom left of the photo and two, one either side of the second from the top circular oilway. 5 August 2017.
Photograph: Darrin Crone.

Lower bearing faces

The refurbished cylinder lubricator, furthest from the camera has been refitted. 5 August 2017.
Photograph: Darrin Crone.

Refurbished cylinder lubricator

The lubricator pipework from the cylinder lubricator has been refurbished and refitted. 5 August 2017.
Photograph: Darrin Crone.

Lubricator pipework

The new sandbox studs have been fitted to the frames and the frames painted. The sandbox can now be refitted. 5 August 2017.
Photograph: Darrin Crone.

New sandbox studs

31 July 2017

The gravity sands mechanism is cable operated from a lever in the cab. The cable opens the sands through the operation of a pulley that operates linkages to the sand boxes. During the inspection and testing of the components a crack was discovered in the pulley wheel. The pulley was removed from its bracket and the crack silver soldered. There are a number of slack pins in the mechanism but to check alignment it has been decided to mount the various brackets on the loco and check fits in situ. The brackets are now being painted and will be fitted to the loco.

The split pin holes were drilled in the gravity sandbox studs this week on the NRM's Richmond radial arm drill. As there were quite a number to do a jig was made up to hold them accurately. The split pin holes in the regulator hanger bolts were also drilled this week.

Work on the tender continued with the removal of various archaeological layers from the back corner of the corridor. Our CME and myself spent some time on the tender on Saturday examining what has been revealed so far and planning the future work. The CME also went into the tank and brought out some of the epoxy coating put on at the last overhaul. I want to check the flammability of this before we use the burning gear on dismantling.

The new rivets put in to the frames last week were dressed. It is important that they do not project too far from the surface of the frames as they could foul the back of the wheels so they were ground back a little just to make sure.

After a break we revisited the leading loco vacuum cylinders this week. We had hoped to have the mounting trunnions trued up and trunnion sleeves machined off on the NRM's borer, however the museum staff have been too busy so the cylinder on the borer was taken off. The approved recovery procedure for worn trunnions is to sleeve them, and this has been done with our cylinders. Now that the sleeves are worn they require replacement so all have now been removed. We will have to use an external contractor for skimming the trunnions.

On Wednesday I and the CME, went to the South Devon Railway to inspect the re-tyred coupled and bogie wheels. As usual at Buckfastliegh we were warmly welcomed by Rob Le Chevalier who kindly peeled back the Denso tape so that we could inspect the finish on the journals and new crank pins. We discussed at length the method of manufacture and the accurate location of the new driving crankpins. All was in order and we were pleased to accept the wheelsets as completed. The inspection included checking all work had been completed to our purchase orders and examining the draft versions of the documentation that will be provided by the SDR. We now only await the final documentation package and the transport of the wheelsets back to York can be organised. The haulier has already been contacted and is standing by.

While away from York work continued on the loco. The repair of the front streamlining mounting holes was progressed. The front corner and centre streamlining was trial fitted and there are only a couple of holes which will need attention. The centre streamlining was removed on Saturday for a final inspection of the front hook arrangement and it was decided that the front hook bufferbeam casting can now be remounted on the loco.

The mudhole doors removed from the boiler at York were retrieved from store, and with the others brought from Grosmont last week were cleaned. The painting bench and packing that were in front of the loco were also relocated. This has freed up an area where the wheelsets can be placed for painting when they return.

This week also saw the completion of the spotfacing and countersinking on the right hand combined brake and spring bracket. On the left hand bracket the bore for the brakeshaft bearing was refaced using a jig and cutter designed and made for the job by the volunteer Engineering Team, and a very good finish was produced.

A view inside the tender corridor looking through the window at the rear of the tender. The original 1928 construction of the tender is evident by the riveting. 25 July 2017
Photograph: Peter Brackstone.

Inside the tender corridor

The front streamlining is trial fitted during the repair of the fastening holes and streamlined panels. 26 July 2017
Photograph: Peter Brackstone.

Front streamlining is trial fitted

The gravity sandbox studs are drilled on a jig to save time setting up for each stud. 27 July 2017
Photograph: Bob Shearman.

The gravity sandbox studs

The driving wheelset at the works of the South Devon Railway. All repairs are complete and the wheelset will be returned to York soon. 27 July 2017
Photograph: Richard Swales.

The driving wheelset

The leading bogie wheelset ready to return to York. 27 July 2017
Photograph: Darrin Crone.

The leading bogie wheelset

The leading and trailing coupled wheelsets have all repairs completed, and as the rest of 60007's wheelsets, they have been subject to detailed inspection by SNG Engineers. 27 July 2017
Photograph: Darrin Crone.

Coupled wheelsets

The removed right hand driving crank pin, bearing number 26 as the wheelset was originally fitted to Miles Beevor. It will be retained as a possible reference in the positioning and fit of the existing valve gear crank to the new crank pin. 27 July 2017
Photograph: Darrin Crone.

RH driving crank pin

The bore of the left hand combined brake shaft and spring bracket has been skimmed to repair the surface. 29 July 2017
Photograph: Richard Swales.

LH brake shaft & spring bracket

Not mentioned in this weeks report but mentioned in previous reports, the new bogie side control bolt to the right, has been fitted with a new key, the nut and cotter have been dressed to improve their fit. 29 July 2017
Photograph: Richard Swales.

New bogie side control bolt

24 July 2017

Good progress has been made with the gravity sandbox studs. They are all now threaded and just require drilling for split pins. The gravity sands operating linkage that goes across the rear of the smokebox saddle was retrieved from store this week and cleaned and inspected. A number of required repairs have been identified which will be addressed during the refurbishment.

The new bogie side control bolt has now been fitted with a cotter and the old nut thread dressed to fit properly. The bolt key has now been machined and is the correct height for fitting the bogie centre casting. The bogie centre casting bearing surfaces have now been machined at the works of K D Flavell. Machining of one face on the underside of the casting removed the oilways, so these have been re-cut. A number of the old retaining screws that hold the plates on came loose during the machining and these will need to be replaced.

Gasket material was obtained this week which allowed a number of joints around the air pump to be permanently made and new joints have been made for the air pump exhaust pipe.

The buffer housings, with secondary buffers and new rubber springs, were fitted to the loco this week. This allows the front corner streamlining to be fitted. Some of the worn tapped securing holes that hold the front corner streamlining were welded up this week. The streamlining was thoroughly descaled internally and primer has been applied. The lamp irons were removed and these will be refurbished as they are heavily worn.

The support beam for the regulator valve was secured in place on the regulator with new bolting that was delivered this week. The long hanger bolts that fasten through the regulator support beam to brackets on the inside of the boiler were machined this week. Final drilling of hanger bolts for the split pin holes is still required.

New bolts were also fitted this week to the joint between the saddle and the middle cylinder. The original bolts were wasted and when removed the flange between the saddle and middle cylinder casting required a lot of work to produce a surface suitable for bolting.

The axleboxes for the coupled wheelsets and bogie were delivered to the NYMR's Grosmont MPD this week where they will be re-metaled and machined. Our reception at the MPD was very welcoming, as usual, and they left us in no doubt that they are very keen to get 60007 back in traffic on the NYMR. While at Grosmont we retrieved the boiler mud hole doors that are now required at Llangollen for refurbishment.

The countersinking of the last hole on the right hand leading combined brake and spring bracket was very nearly completed this week. The hole is taking longer that the last hole contersunk due to the countersink having to cut in to a weld to one side of the hole.

The machining of the faces of the bronze regulator stuffing box was returned to York this week, being carried out by a member of the volunteer Engineering Team, and what a magnificent job it is.

The riveting of the leading brake cylinder stretcher was completed this week, after having to stop the job a couple of weeks ago due to a fault with the workshop doors. After the large end rivets were fitted a couple of the smaller rivets on the stretcher central strengthening web were also fitted. There are still a couple of the smaller ones to be done. The new large end rivets were hammer tested and proved tight.

The bogie centre casting on the large horizontal borer in the works of K D Flavell having the lower bearing faces skimmed. 17 July 2017
Photograph: Darrin Crone.

The bogie centre casting

The underside of the loco bogie stretcher was di-pen inspected this week. No faults were found. In this view the leading right hand underside of the stretcher can be seen with the vertical row of bolts that hold the front of the outside cylinder on to the frames. 18 July 2017
Photograph: Darrin Crone.

Underside loco bogie stretcher

Overhaul webpage favourite, Alan Pitt, needle guns the inside of the front corner streamlining. 18 July 2017
Photograph: Peter Brackstone.

Inside front corner streamlining

Dave Lee has been welding up worn threaded holes that secure the front streamlining. Here he grinds excess weld from the front right hand footplate angle. 19 July 2017
Photograph: Peter Brackstone.

Welding up worn threaded holes

The coupled wheel and bogie axleboxes have now been delivered to Grosmont for re-metalling and machining. 20 July 2017
Photograph: Peter Brackstonee.

Coupled wheel, bogie axleboxes

Some of the components that make up the gravity sander operating mechanism. The parts have been inspected for defects and will now be refurbished. 22 July 2017
Photograph: Darrin Crone.

The gravity sander mechanism

The mud hole doors from 60007's boiler were in store at Grosmont having been removed from the boiler when the loco came out of traffic in 2015. They have now been moved to York. They will be cleaned up and sent to Llangollen for refurbishment and fitting to the boiler. 22 July 2017
Photograph: Darrin Crone.

The mud hole doors

The front buffer housings were were put back on the front bufferbeam this week. 22 July 2017
Photograph: Darrin Crone.

The front buffer housings

New rivets have been fitted to the leading brake cylinder loco stretcher. This is the right hand side where three new rivets have been fitted. Similarly the left hand has required three new rivets. By the appearance of the frames in this area this is a job that has been carried out a number of times in the locos history. 22 July 2017
Photograph: Darrin Crone.

New rivets have been fitted

The regulator stuffing box faces have been re-machined and the pad that locates the regulator rod pin machined to give the correct offset. The finish and fit is superb. 22 July 2017
Photograph: Darrin Crone.

Regulator stuffing box faces

New bolts have been fitted to the regulator support beam, one just visible in the photo. The long regulator valve hanger bolts are laid on the valve with a cut off old bolt still in the support beam to indicate its position, though the bolt is screwed in to the other side of the beam when fitted. 22 July 2017
Photograph: Darrin Crone.

New bolts have been fitted

New bolts have been fitted to the joint between the saddle casting and the middle cylinder casting, the culmination of a considerable amount of work in preparing the casting surfaces. 22 July 2017
Photograph: Darrin Crone.

New bolts have been fitted

16 July 2017

Good progress is being made with the refurbishment of the superheater header. A special tap has been sourced to tap the end cover holes. This has been loaned to us from the collection of special railway taps in the Engineering Workshops of the NRM. It must be very old but still feels sharp. The header casting is stood on end and the welded areas have been ultrasonically examined for thickness.

The loose countersunk screws that hold on the bogie bearing plates on the top of the bogie frames have now all been refitted with the addition of thread locking solution. Three screws were not recoverable and had to be remade. These were machined and fitted on Saturday.

The studs for mounting the gravity sandboxes are now being finished. The thickness of the flanges on the sand boxes have been measured, and the studs are being drilled for the split pin holes. The hole is positioned so that the split pin fits closely against the tops of the nut when the sandbox is fitted in place.

The small ejector from the vacuum brake ejector has now been refurbished. The seat of the ejector valve has been skimmed and so has the valve. It will now require assembly and a final lapping.

Work on the refurbishment of the regulator stuffing box continues. The skimming of the flange face of the body casting has been completed. It is reported that the material is very tough and wears cutting tools very rapidly. The cover is yet to be machined.

Work continues on the loco bogie stretcher with di-pen inspection of the top of the flanges that bolt through to the loco frames and the end plates that were welded by LNER or BR to strengthen the stretcher casting. No faults were found. The new plates we are to have welded in to the bogie stretcher were fitted this week. The square edged profiles plates had to be ground accurately to allow a good fit into the radii and webs of the stretcher casting. The loco bogie side bearer brackets were returned to York this week with the cracked RH bracket repaired.

There are two holes left to machine on the RH combined spring and brake bracket. As reported previously all the holes requiring spotfacing have been completed, the remaining two require countersinking. The first of these were completed this week with a special tool made by Engineering Team volunteers. The set up has now been moved to the last hole.

We received the new front buffer rubber springs this week. The centre holes through which the buffer shank passes were deburred and the ones that are fitted in to the buffer housings were assembled with the secondary buffers in to the housings. The frames behind the bufferbeam received their last coats of gloss this week. We'll give the paint a few days to harden then we'll refit the buffer housings. When the buffer housings are on we can refit the front corner streamlining, however some of the tapped mounting holes for the streaminling are worn and a start was made this week on welding up these holes so that they can be remade.

Work continued on cleaning and descaling the tender. Work on the front continues but we are also now working on cleaning the worst off between the frames. Needle gunning has continued on the front while other Engineering Team members went between the frames to clean off the pipework and water valves under the front of the tender.

The air pump exhaust piping was refitted this week and while the Pipe Fitting Team were confined between the loco frames they did some more work on the air brake piping.

The exhaust pipe from the air pump is now fitted.
Photograph: Peter Brackstone.

Air pump exhaust pipe

The small ejector valve has had to be re-machined to remove a large steam cut from the valve seat. 15 July 2017
Photograph: Darrin Crone.

The small ejector valve

The worn tapped holes in the footplate angles that the streamlining is fastened to are being welded up. They will then be dressed and the holes remade. 15 July 2017
Photograph: Darrin Crone.

The worn tapped holes

After cleaning and scraping the left hand water valve under the front of the tender. 15 July 2017
Photograph: Darrin Crone.

Left hand water valve

One of the side bearer plates added later in the life of the bogie. Two of the countersunk screws had to be replaced as they were life expired. The new screws are made with a reduced section just above the countersink so that when sufficient torque is applied the head it breaks off. The centre sheared section will be ground down. 15 July 2017
Photograph: Darrin Crone.

One of the side bearer plates

The underside of the footplating has been finished in gloss paint. Not an easy or pleasant job to paint over your head for hours, so well done to the Painting Team. 15 July 2017
Photograph: Darrin Crone.

Underside of the footplating

The loco bogie side bearer brackets were returned to York this week. The right side was cracked and this has been repaired. 15 July 2017
Photograph: Darrin Crone.

Loco bogie side bearer brackets

9 July 2017

On Monday the patterns for the clack boxes were taken to the South Lincs Foundry. There were three storage boxes filled with wooden patterns and they are expensive to make so it was decided to deliver them personally. They were safely delivered and next day discussions were under way with the pattern maker at the foundry concerning the modifications we need to the fireman's side clack box to maintain the appearance of the version we have in the cab of 60007.

At York our new bogie side control bolt was inspected, comparing it to our drawing. It checks out OK. A new key will be required for the bolt so new key steel was purchased and a key made to fit. Some final machining of the key is required to reduce its height. The bolt goes through the bogie chassis and the bogie centre casting. This casting was transported to contractors for machining last week and this week the contractors were visited and the dimensioned instructions prepared by our CME were delivered and discussed. The casting was put up on a borer on Friday for setting up and machining will begin on Monday.

The leading brake cylinder stretcher had its final loose rivets removed this week. Temporary bolts were put through to keep everything tight. On Saturday the Engineering Team assembled to put the first rivets through the bracket and frames. After a couple of false starts, not unusual when setting up for this kind of job, we got our first rivet home and tight. We were ready to get in to our swing when we were told we had to leave the workshop as there was a problem with the locking of the doors which made the workshop unsafe for us. This prevented me from taking some photos for this report.

Work has been carried out on the tender most of this week with attention being concentrated on the front, removing corrosion and a solid block of compacted coal dust inside the front structure. The needle gun and plenty of scraping and chipping has been carried out. Staging has now been put up in front of the tender to improve access and safety as we work our way up.

The overhaul of the brake ejector continued this week, with its internal condition being very good. We have found a steam cut on the small ejector valve seat, which will have to be machined and the valve will be dressed at the same time. Various glands have now been repacked and some covers now reassembled and sealed.

The superheater header was inspected at our contractors this week and we are very pleased with progress. The superheater was sent with a comprehensive work scope that they are working through. The top surface and one of the corners have already been built up.

It has been decided to put plates in the bogie stretcher that will provide additional support to the middle of the stretcher cover plate. The plates have been specified and an order was placed this week for them to be profiled. They will be welded in place after final fitting.

Further work was done on the air brake piping this week, with further pieces put up on the loco and a new section of pipe used to replace a piece that shows some heavy wear. The air pump exhaust steel pipes were stripped this week and after inspection were given a coat of primer prior to fitting.

The refurbished coupled wheel springs were returned to York this week, and await inspection.

The black pipes are the steel air pump exhaust pipes and this is their condition from store. They have now been stripped, inspected and primed. 29 June 2017
Photograph: Darrin Crone.

Air pump exhaust pipes

This week the front of the tender has been worked on. The needle gun, one of our favorite tools is used on the front dragbox. 4 July 2017
Photograph: Peter Brackstone.

Front of the tender

The fireman's side clack box casting we are to replace. I am willing to consider outrageous financial offers for this unique artifact. 7 July 2017
Photograph: Darrin Crone.

Clack box casting

At the works of K D Flavell the superheater header is welded vertically to a heavy steel beam to ensure no distortion and making it easier to move during refurbishment. 7 July 2017
Photograph: Darrin Crone

Superheater header

Also at the works of K D Flavell the loco side bearers that stop excessive rolling of the loco by contacting the bogie side bearers. One was cracked and this has now been repaired. However both side bearers have been examined. 7 July 2017
Photograph: Darrin Crone.

Loco side bearers

2 July 2017

On Tuesday welding contractors visited us and carried out a series of repairs identified as being required during the frame survey. This included rebuilding the thickness of the frames under the cab where corroded and also repairing the leading left combined spring and brakeshaft bracket. During examination this bracket was found to be cracked. This is the matching opposite bracket to the right hand that was removed from the locomotive for extensive refurbishment. These brackets obviously experience high stresses in operation. The spotfacing of the right hand bracket was completed this week but there remains the countersinking of two rivet holes.

On the same day our refurbished pistons were delivered to us. Due to the wet weather as soon as we got them inside we made sure they got a rub down. They have had their heads rebuilt and machined to give us the correct clearance in the cylinder bores and the ring grooves squared up, as over time they taper out due to the movement of the piston rings.

Last week the superheater header end plugs were removed, which completed the work we are doing to the header, for now. The header was dispatched for refurbishment this week with a full specification of required works.

The bogie centre casting that goes between the loco stretcher and the bogie frame was also sent to contractors for repair this week. The bearing surfaces have worn and there is an area of corrosion on one of the lower faces. The top face will be skimmed and the lower faces machined to the offsets measured on the bogie frame bearing surfaces to ensure the assembly sits true and level. Some of the screws holding the bogie bearing plates were found loose when the bogie was removed from the locomotive.The examination of the rest of the screws has begun and additional loose examples have been found. We have now began the process of removing the loose screws and cleaning out the holes. The screws are countersunk and do not have any means of driving them so it is not easy to remove them.

Painting continues around the front of the loco with undercoat being applied to the leading sections of the outside frames. The tapped holes in the footplate angles where the streamlining is attached has been tapped out to clean them of paint and they have been examined. Some holes are worn and will have to be repaired so that the footplating screws can be securely fixed. We also looked at the tapped holes on the outside cylinders. Some of these are in a very worn state and will also require repair.

The leading middle cylinder steam chest studs were examined this week as they become relatively inaccessible when the valve is in position. Some were not fitting correctly so the offending studs were removed and correctly refitted. They are in better condition than the cylinder cover studs we replaced. The coverplates from the tops of the couple wheel axleboxes were removed this week and the dispatch of the axleboxes for contractor repair will now be finalised.

Additional pipework was retrieved from store this week, including the air brake pipework that runs along the loco mainframes and the air pump exhaust pipework. The pipework is now being cleaned and prepared for refitting. Some of the air brake pipework has now been refitted.

We have been informed that the refurbishment of the coupled wheel springs has now been completed and they are ready for shipping back to York. The new valve liners are presently at specialist grinders for final finishing to size.

The vacuum ejector overhaul began this week with its retrieval form store and preliminary stripping and examination.

The repaired pistons were returned to York this week. 27 June 2017
Photograph: Peter Brackstone.

Repaired pistons

Welding contractors carried out repairs to the frames this week. Allen Flavell of K D Flavell welds the left hand combined bracket. 27 June 2017
Photograph: Peter Brackstone.

L/H combined bracket

The front corner streamlining was retrieved from store and cleaned this week. It will be trial fitted to test the fastening holes in the footplate angles. 29 June 2017
Photograph: Peter Brackstone.

Front corner streamlining

The last hole in the right hand leading combined spring and brakeshaft bracket requiring spotfacing was completed this week. 29 June 2017
Photograph: Darrin Crone.

The last hole.......

The left hand leading combined combined spring and brakeshaft bracket was weld repaired in-situ. When examined during the survey of the frames the bracket was found to be cracked. 29 June 2017
Photograph: Darrin Crone.

L/H spring & brakeshaft bracket

Air brake pipe runs have been mounted on the frames. They can be seen as two parallel pipes running along the top of the frames. 29 June 2017
Photograph: Darrin Crone.

Air brake pipe runs

The brake ejector on the bench. Its overhaul began this week. 29 June 2017
Photograph: Darrin Crone.

Brake ejector on the bench
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