Painting team leader Peter Brackstone applies the first coat of gloss to the coupled wheels.
Photograph: T Camp/SNGLT.

The trailing coupled wheelset make a fine sight with a complete first coat of gloss.
Photograph: T Camp/SNGLT.

At Llangollen the firebox crown plate has been lowered at the tubeplate end and a template of the new tubeplate tried in place.
Photograph: Paul Aston.

The injectors and damper cross shaft have been fitted to allow the accurate positioning of the pipework beneath the cab.
Photograph: Darrin Crone.

New bushes are being fitted to the drain cock valves to mininise steam leakage around the valve spindles. Two of the old bushes are in the foreground.
Photograph: Darrin Crone.

The boiler blanking plates will be fitted to the boiler during testing to close up the holes where the boiler fittings are located.
Photograph: Darrin Crone.

The middle upper slide bar on the forklift on its way to be measured for flatness of the surface the crosshead runs against.
Photograph: Darrin Crone.

The studs have been removed from the superheater face where the middle steam pipe connects. This will allow the full face to be repaired and dressed.
Photograph: Darrin Crone.

The cylinder drain cocks have two integral valves. An automatic pressure relief valve and a poppet valve operated by the driver to allow the cylinders to be drained. Both parts of the six valve units have now been overhauled.
Photograph: Darrin Crone.

The coupled wheels have now received two coats of black gloss. Nearly there just the varnishing to be done.
Photograph: Darrin Crone.

The coupling rods now next to the engine. There overhaul has started.
Photograph: Darrin Crone.

The cab floor plate extends the full width of the loco with its outer edges forming the footplating outside the cabsides.
Photograph: Darrin Crone.

The boiler is now on its back to allow work on the roof plate in the combustion chamber. The boiler was taken in to the yard at Llangollen and when turned returned to the workshop.
Photograph: Paul Aston.

The cylinder drain cocks have been refitted temporarily to the outside cylinders to allow the operating linkage to be located and examined for fit.
Photograph: Darrin Crone.

The superheater header middle front plate is in front of the header. The face that seals against the header has been thoroughly cleaned off and examined.
Photograph: Darrin Crone.

The lower surface of the cab floor plate cleaned and now with a coat of undercoat.
Photograph: Darrin Crone.

The floor plate sits across the rear of the loco frames so the painting of this area has also been carried out so that it can be fitted.
Photograph: Darrin Crone.

The first two new valve heads have been delivered to the NRM for inspection and they are very good. When we receive the final two all will have the centre key ways cut in them.
Photograph: Darrin Crone.

The bogie wheels are finished in gloss and are receiving a bit of tidy up around their edges. They are yet to be varnished.
Photograph: Darrin Crone.

The bogie axle boxes were delivered last week and I overlooked including a photo of them. Here they are on the pallet in the NRM workshop.
Photograph: Darrin Crone.

The clackboxes are being machined by TT Elecmech of Darlington. One of the castings is on the lathe having the valve threads cut.
Photograph: Tom Jones.

New plate in the front left of the ashpan.
Photograph: Darrin Crone.

The crankpin bushes were pressed out of the coupling rods this week and the rods are shown set up for measurement.
Photograph: Darrin Crone.

The leading right coupling rod bush. The key stops the bush from rotating in the rod and the oily felt controls the flow of lubricating oil to the crackpin. The ring is fitted between the rod and the wheel to provide a side thrust bearing face.
Photograph: Darrin Crone.

The dragbox area of the loco is receiving further coats of paint before the floor plate is fitted and prevents further access.
Photograph: Darrin Crone.

The superheater header element holes are being reamed to take out ovality and taper.
Photograph: Darrin Crone.

The brake gear removal from the tender continues.
Photograph: Darrin Crone.

The GSMR equipment is mounted on a rack fitted in the tender corridor vestibule. It has been dismantled and is being repaired and prepared for repainting.
Photograph: Darrin Crone.

The clackboxes at the works of TT Elecmech where they are being machined. The reconditioned valves are fitted to the clackbox castings to check fit and allow an intermediate pressure test.
Photograph: Darrin Crone.

At Llangollen the new firebox tubeplate is being marked for its flange to be drilled prior to fitting.
Photograph: Paul Aston.

The regulator cross shaft and stuffing box have been trial mounted on the backhead of the boiler.
Photograph: Paul Aston.

The right side coupling rods have had their bushes pressed out and are being examined for defects.
Photograph: Darrin Crone.

The platework that stands on the cab floorplate and supports the wooden floor. The green primer painted plate can be reused, the plates beyond require replacement.
Photograph: Darrin Crone.

The left outside connecting rod has had its bushes removed and is measured. The rod projecting from the big end bearing hole allows a long internal micrometer to be used to check the bearing centres.
Photograph: Darrin Crone.

The six lower slidebars have been on the surface table in the NRM Workshop and been measured for wear.
Photograph: Darrin Crone.

The reaming of the superheater element holes continues.
Photograph: Darrin Crone.

The bogie wheelsets have been moved back on to the rail in front of the loco.
Photograph: Darrin Crone.

The inspection of the coupling rods has continued with the ends inspected for cracks.
Photograph: Darrin Crone.

The tender coal space and the top of the corridor is being descaled. A large amount of material has been removed.
Photograph: Darrin Crone.

The little end, or gudgeon pins have been thoroughly prepared for examination. They have now been measured for wear.
Photograph: Darrin Crone.

The tyre edges on the bogie wheels have been cleaned off, the trailing set has been turned round to get it the right way round and the protective covers removed from the journals. The wheelsets sit on the NRM workshop wheel drop, originally part of York North depot.
Photograph: Darrin Crone.

The ashpan back right back corner has received further new plate.
Photograph: Darrin Crone.

The inside connecting rod has been retrieved from store, cleaned up and a start made on measuring it as part of its examination.
Photograph: Darrin Crone.

The clamp that pulls the regulator valve on to the internal steam pipe inside of the the boiler barrel was retrieved from store this week and prepared to be sent to Llangollen.
Photograph: Darrin Crone.

At Llangollen work progresses on the tube plate and the regulator set up. This photo shows inside the stuffing box on the backhead with the reach rod that goes through the boiler to the regulator valve.
Photograph: Paul Aston.

The floor plate is lowered in to position by Roger Turnbull and Ian Seales.
Photograph: Malc Bateman.

The rear cab upstand is lowered in to position.
Photograph: Trevor Camp/SNGLT.

The bogie wheel journals and thrust faces are polished to a high standard before fitting the axleboxes. The wheelsets sit on the NRM workshops wheeldrop.
Photograph: Peter Brackstone.

The bogie axleboxes are in the process of being fitted. Andy Lowes puts in the oil wedges on the left side boxes.
Photograph: Richard Swales.

The outside upper slidebars have been inspected for possible cracking around their mounting holes. No defects have been found.
Photograph: Darrin Crone.

The right side bogie axleboxes have been fitted and are put to one side.
Photograph: Malc Bateman.

Not mentioned in the report but measuring the moving parts of the locomotive continues. Here the inside connecting rod receives the attention of the Chief Mechanical Engineers micrometers.
Photograph: Darrin Crone.

The rubber springs for the bogie and coupled wheels were assembled this week. Supplied as separate steel and rubber plates they are glued together with a high strength two part adhesive.
Photograph: Darrin Crone.

The upper middle slidebar is inspected for defects around its mounting holes. All the slidebars are inspected like this before refitting. They have also been measured for wear.
Photograph: Darrin Crone.

A new section of platework has been let in to the fireman's side cab floor support to replace wasted plate.
Photograph: Peter Brackstone.

The superheater header refurbishment continued this week with the reamed element holes deburred.
Photograph: Darrin Crone.

The cylinder relief valves are dismantled, cleaned, inspected and refurbished. The parts of each valve being kept together.
Photograph: Darrin Crone.

The cylinder drain operating linkages have been refurbished and is being trial fitted.
Photograph: Darrin Crone.

Now that the cab floor plate is fitted pipework begins to emerge.
Photograph: Darrin Crone.

The new copper tubeplate is now in position, in the upturned boiler.
Photograph: Paul Aston.

The left piston crosshead has been inspected for damage and defects. No faults were found.
Photograph: Darrin Crone.

The cylinder relief valves have been overhauled.
Photograph: Darrin Crone.

The left upper sidebar has been accurately positioned.
Photograph: Darrin Crone.

The cab floor structure is in position, though more fitting is required.
Photograph: Darrin Crone.

Safety valve components are on the surface table being inspected and measured.
Photograph: Darrin Crone.

The combined timing reservoir is mounted to the leading transverse cab floor upstand. A view looking toward the driver's side. Primed plates are existing plate, unpainted plate is new.
Photograph: Darrin Crone.

The large heavy casting that is the main part of the reverser stand. Laid on its back it normally stands on the base in the front of the photograph. Here most of the paint has been removed prior to testing for defects.
Photograph: Darrin Crone.

The reverser stand and the screw that operates the reversing links and gear, that is normally down the middle of the stand.
Photograph: Darrin Crone.

The right upper slide bar is in position and aligned with the wire from the cylinder centre line.
Photograph: Darrin Crone.

A section of the outer layer of the tender corridor roof has been removed. Over the top the end of the streamlining can be seen where a section has been cut away. The streamlining was added to the original 1928 tender when it was transferred to A4 use. Under the streamlining is the original beading that marks the top of the 1928 tender.
Photograph: Darrin Crone.

The tender brakeshaft is being stripped and descaled for inspection. It is seen here with its end brackets in place. It is mounted at the front of the tender frames.
Photograph: Darrin Crone.

The drain cock cab Bowden pulley, marked for sands but so is the sands one.
Photograph: Darrin Crone.

A view looking toward the front right of the tender with a section of tender corridor removed. On the outside the A4 fairing has also been removed. The beading which was the top of the original 1928 tender can be seen.
Photograph: Darrin Crone.

The gap between the middle cylinder alignment wire and middle upper slidebar is measured with a micrometer by Chief Mechanical Engineer Richard Swales.
Photograph: Darrin Crone.

The loco brake hangers are being rebuilt with weld where the cast iron brake blocks rub and wear away the hanger.
Photograph: Darrin Crone.

The air brake components have been returned from contractor overhaul and are being positioned under the cab floor. The nearest valve is the FVF2, but it's bigger than the old unit so won't fit in the same place.
Photograph: Darrin Crone.

The piston rod taper jig in place in the right crosshead.
Photograph: Richard Swales.

The removal of the corridor plate work from the tender is ongoing.
Photograph: Peter Brackstone.

The reverser column has been cleaned tested and prime painted.
Photograph: Peter Brackstone.

A view of the tubeplate from the firebox side.
Photograph: Richard Swales.

Our CME closely inspects every inch of the tubeplate joint inside the boiler at Llangollen.
Photograph: Darrin Crone.

The bogie frames, wheelsets and suspension components brought together for assembly, if only we could get close enough to put them together but the painting team won't let us anywhere near them during varnishing.
Photograph: Darrin Crone.

The middle crosshead is thoroughly cleaned prior to examination for defects and measurement of piston rod taper centre from bearing surfaces.
Photograph: Darrin Crone.

The middle crosshead is inspected for defects and cracks.
Photograph: Richard Swales.

The horizontal hornstay bolt holes are reamed. Accuracy and care is needed as the minimum material must be removed. Tony Bickerstaffe operates the magdrill assisted by Roger Turnbull.
Photograph: Richard Swales.

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Photograph: Darrin Crone.

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Photograph: Darrin Crone.

The cast bronze discs that fit between the bogie and the loco. They are 26 ½" diameter.
Photograph: T. Crone.

The coach was shunted in the NRM's North Yard so that the DB loco could come straight on to the coach.
Photograph: Darrin Crone.

Not mentioned in the report the reverser reach rod di-pen inspection was completed this week.
Photograph: Darrin Crone.

In the early evening the DB 66 is seen coupled to the coach ready to leave for the short trip over the network to the Holgate Engineering Works.
Photograph: Malcolm Bateman/Trevor Camp/SNGLT.

At the Holgate Engineering Works the coach is winched on to the low loader.
Photograph: Peter Brackstone.

At Cranmore the coach is winched off the low loader.
Photograph: Nigel Wilson.

A section of the new air brake pipework before fitting in the loco. The curved pipes furthest from the camera are recovered from the current installation.
Photograph: P Ellis.

The superheater header will need fitting with new studs where the middle cover is fitted. The thread depths are measured so that the correct size of studs can be specified.
Photograph: Darrin Crone.

The piston valve heads are being slotted where they are keyed on to the valve rod.
Photograph: Darrin Crone.

The inside of the smokebox door is needle gunned.
Photograph: Darrin Crone.

Two of the new valve heads have been slotted, one is setup on the machine and one to do.
Photograph: Darrin Crone.

The bronze bearing discs that are fitted between the loco and bogie are being machined. One has been faced the other is still a raw casting.
Photograph: Darrin Crone.

The trailing vacuum cylinder was lifted in to the frames and secured.
Photograph: Mike Page.

The new piston valve heads are fitted to the valve spindles. Only the middle and right valve heads are new as it was only these valve liners that required renewal.
Photograph: Darrin Crone.

The drain cock bodies in which the pin holes were found have been repaired. All the outside draw-in cocks have had the side slots rebuilt.
Photograph: Darrin Crone.

Decades of paint, bitumen and filler have been removed in the corridor to determine the condition of the tank. This is a view in to the vestibule end.
Photograph: Darrin Crone.

The base of the reverser has a shaft that rotates and operates the reverser reach rod. The bearing nearest the arm has been re-machined and fitted to remove wear.
Photograph: Darrin Crone.

New bolts have been fitted to the leading top of the saddle. These go through the saddle, frame plate and left hand cylinder. The upper left only fits if the head is shaped and the face for the head was cut with chisels.
Photograph: Darrin Crone.

Parts of the AWS/TPWS assembly that is fitted to the front and underneath of the bogie.
Photograph: Peter Brackstone.

The axleboxes are lowered on to the journals of the bogie wheelsets, guided in to position by Peter Brackstone, watched by CME Richard Swales.
Photograph: Trevor Camp/SNGLT.

With all the axleboxes in place the frames are lowered. A member of the Engineering Team at each corner to ensure that the axleboxes enter the bogie frame horns.
Photograph: Trevor Camp/SNGLT.

The axleboxes entering the horns as the bogie frames are lowered.
Photograph: Trevor Camp/SNGLT.

After the frames are down on the axleboxes the weight is held on the crane while the hornstays are refitted. The hornstays close the gaps in the frames under the axleboxes.
Photograph: Trevor Camp/SNGLT.

The assembled bogie stood on the wheel drop in the MRM workshop.
Photograph: Richard Swales.

The right hand return crank has been removed from its rod and tried on the crank pin.
Photograph: Darrin Crone.

The expansion links are now ready for testing and measuring.
Photograph: Darrin Crone.

The sling stays at the front of the firebox, that provide flexibility are being fitted at Llangollen This view shows the crown or roof of the firebox as the boiler is still on its back. The projecting stays will be trimmed back and nuts fitted to protect the ends from the fire.
Photograph: Paul Aston.

A view inside the boiler showing how the stays are fixed to the outer firebox.
Photograph: Paul Aston.

The radius rods are also being examined for defects. With the valve covers these are components that link the driving crankpin to the piston valves. The red is the penetrant dye that will enter any small surface defects or cracks, that will show up when a dry white coating is applied.
Photograph: Darrin Crone.

The plates above the cylinders removed to gain access to the cylinder mounting bolts has now been refitted. On these plates are the leading lubrication oil boxes, which have been overhauled and are now refitted.
Photograph: Darrin Crone.

The AWS (Advanced Warning System) brackets have been refitted to the bogie.
Photograph: Darrin Crone.

The lifting arms that control the valve travel are also being examined. At the left end can be seen the die block that slides in the radius rod. The die blocks and pins have been checked for wear.
Photograph: Darrin Crone.

The trailing valve chest covers are being examined before refitting.
Photograph: Richard Swales.

The bogie spring beams have been dressed to be a good fit on the bogie hanger bolts to stop the bolts turning when their loading is adjusted. The new bolts are to drawing and have larger heads that the bolts they replace.
Photograph: Darrin Crone.

The left return crank is from 60026, as can be seen under the "07" stamping. Why they bothered to do this as 60007 would never go through works again at the same time as 60026, or any other A4s for that matter.
Photograph: Darrin Crone.

The spherical ball bearing from the return crank rod. The bearing takes up any variation in the alignment between the valve gear and the driving wheelset. The bearing is historical, made by Ransome and Marles, who also made all the roller bearings for the original A4 valve gear.
Photograph: Richard Swales.

The ashpan is moved under the crane to allow it to be lifted in to the frames.
Photograph: Peter Brackstone.

The diaphragm plate being lowered in to position. It fastens to the bogie stretcher below, and it fixes the position of the rear of the ashpan and boiler.
Photograph: Peter Brackstone.

The ashpan is lowered in to the frames. The cab has to be removed for this and is placed to the rear of the frames.
Photograph: Peter Brackstone.

The manifold is returned from store and the end fitting for the steam sands shut off valve is being fitted.
Photograph: Darrin Crone.

The "new" steam heat shut off valve has been returned from repair after having a new body cast. This will be mounted on the manifold.
Photograph: Darrin Crone.

The slidebar shims have been profiled and dressed before going on to the surface grinder for accurate finishing.
Photograph: Darrin Crone.

The AWS carrier, brackets and receiver have been fitted to the bogie.
Photograph: Darrin Crone.

The TPWS aerial has been fitted as the final reassembly of the bogie continues.
Photograph: Darrin Crone.

The left expansion link trunnion bearing assembly components are laid out on the left slidebar during the inspection process.
Photograph: Darrin Crone.

The top bearings on the reverser column that support the reverser screw nut. New bearings have been fitted and the removable housing on the far side has required realigning.
Photograph: Darrin Crone.

The union links have been inspected for defects as part of a program of inspection of all the valve gear.
Photograph: Darrin Crone.