Final Week

During the week, the filters and operating rods removed from Gervase last week were cleaned up, 

the drive chain was removed and, together with the engine sump, was steam cleaned to remove all the muck.

Ther mesh screen above the sump was partially blocked by white metal that had dropped on it from a run bearing some years ago and then solidified again.  This was heated to melt the majority of it out and a small drill was run through any holes that were still blocked.

The cab repaint has now been completed 

so the running plates were next to be rubbed down and given a coat of primer 

followed by the engine unit getting washed down with paraffin and then rubbed clean.

A spare engine was delivered and this will be cannibalised for parts as necessary.

More bits of 4253’s cladding were rolled and then trimmed to size 

and the boiler’s expansion brackets were bolted up to check the fit.

Sunday’s workforce was a little depleted it being Mother’s Day but we removed the end wall from the boiler house in preparation of the 541 tender tank being removed shortly, 

more of Gervase’s engine valves were ground in 

and the exhaust camshaft extracted from the spare engine.

Yet more cladding sheets were rolled to shape for 4253’s boiler

and the backhead cladding jigsaw is now nearing completion with all the plywood templates shaped to fit, the sizing transferred and marked on the steel sheets

and it just remains to cut the various holes.

Week Four

Work has continued on the boiler cladding with more sections trial fitted, marked and trimmed to size. 

The retaining band clamps were pulling the ends of the bands out of alignment so they were heated and reshaped to prevent this happening.

The plywood template for the backhead cladding was cut into sections 

and then offered up to check for fit before the shape is  transferred to the steel sheet.

At the smokebox end, the main steam pipes were temporarily fitted to the steam chest and the new, machined ends were fitted to the superheater header so we can work out the shape of the bit we need to make to join these two parts together.

On Gervase, the buffer beams were rubbed back to metal 

and a coat of primer applied, the cab received its first gloss coat 

and the side panels which were painted last week were also rubbed back in preparation for a second coat.

The gauges were delivered and these are currently being stripped and cleaned prior to going away to be calibrated.

The engine also received further attention with all the valves being stripped out 

and then cleaned with this shot showing a mix of before and after.

We also found that, with the loco standing for so long, water had got into both the engine and gearbox so the oil was drained from both.  What came out was such a horrible, emulsified mess 

that the sump was removed to enable it and the mesh filter to be thoroughly cleaned out.

Week Three

More of the same this week with cladding sheets being put up, marked, taken down, trimmed using the plasma cutter 

and then put back on the boiler and ratchet strapped tight to the crinoline to re-check the fit.

We also made some of the cladding retaining straps and cold riveted the clamping brackets to the ends.

More of the copper pipework was made with ends brazed on, 

the pipe filled with sand and then heated and bent to shape followed by trial fitting.

The machined ends were tig welded onto the main steam pipes 

and the condensing coil was refitted to the cab roof so that, when it goes back on, we can run the pipes to that.

Work on Gervase is progressing with more of the pipework getting painted, 

the side panels receiving an undercoat 

and the bunker 

and front panel getting a gloss coat.  

Additionally, we’ve started taking the engine apart to free up any seized components and clean it all up.

Week Two

Now that 4253’s crinoline bands are all finished and in position, the next job is the cladding sheets.  Tuesday started with the firebox end sections being run through the rollers again to tighten up the curve radius 

followed by lifting it into position 

and trial fitting it followed by some necessary fettling.

Meanwhile, others were continuing with the pipework which involved refitting the vacuum pipe from the brake ejector on to the train pipe after its modification and the pipes for the front-end lubrication being bent and cut to fit the shut off valves on the smoke box side.

On Friday, the front sections of the Lobo were taken down in preparation for fitting the front cladding sheets which were also passed through the rollers again to tweak their curvature.  The main steam pipe sections from the cylinders were faced in the lathe and a weld prep turned on their ends ready for welding.

On Sunday, both injectors had the outstanding pipework completed and fitted from the steam valves and were then joined and brazed to the pipes coming up from the injectors.

The backhead is now starting to look a bit more complete.

After taking measurements from the boiler barrel, the fireman’s side front cladding sheet was marked and cut to fit round the front cradle, 

carried into the shed and lifted into position for more marking, taken down for final cutting and then trial fitted.

The driver’s side sheet was then completed and both taken down to give access for the next section behind the cradle.  All the remaining sections are more complex as the barrel behind the cradle is tapered with the top surface sloping upwards towards the firebox while the bottom surface remains level.  This means that the remaining cladding sections needed to be cut as reducing cones.  We started with the fireman’s side again which was lifted into position,

clamped and ratchet strapped down and then measured and marked for cutting.  

It was then removed and an angled section cut away to enable the front to fit flush to the cradle 

before being replaced to be marked for cutting the back edge to size.

Work has also been progressing on Gervase with the roof panel getting its gloss coat,

the coal bunker being removed, cleaned, rubbed down and given a coat of primer, 

the front section removed 

and a start made on repainting the sides.

All told, a good week’s work.

Week One

This week, the mammoth task of fabricating and fitting the crinolines to the boiler and firebox was finally finished and it’s all now in place.  The next job will be trial fitting the cladding sheets.

With all the crinoline bands in place, this enabled us to shape and lay the lubrication pipes that run from the backhead, along the side of the boiler to the shut-off valves on the smokebox.

More of 4253’s pipework was completed with the pipe from the vacuum tank to the duplex gauge fitted and the regulator handle and jockey valve’s linkage temporarily fitted to ensure that no pipes foul them throughout their arc of movement.

The flanges for the injector pipes were machined, 

brazed onto the pipe ends 

and then fitted to the injectors.  Some of the smaller pipework from the lubricator to the condensing coil was also heated and  bent to shape ready to fit.  Work was started on the main steam pipes with measuring and marking the position of the necessary holes in the sides of the smokebox 

followed by cutting the holes 

and then trial positioning the straight sections of pipe that attach to the cylinders.

As usual, Mac was working away on more of the backhead cladding panels involving much measuring, cutting, drilling and bolting together.

Work has also continued on Gervase with more rubbing down of old paintwork within the cab, 

another coat of gloss applied to the inside of the cab roof 

and a refurbishment of the vacuum brake application valve.