Week Four

Work on 4253 this week has been exclusively cladding with the bits welded together last week getting dressed back and painted, 

more retaining bands being cut to length 

and the end brackets cold riveted on and the backhead jigsaw having more bits cut and added.  At least with the departure of the 541 tender tank there is more room to lay out all the parts for this.

Work on 5164’s new bunker continued on two fronts – further dismantling of the old bunker to salvage reusable parts we need and the trial build-up of the new panels to check fit etc.  For the former, we found we needed the three support struts that run up the curved rear panel and also to access the underneath to take measurements for the fixings that join the water space floor to the loco frames.  Accordingly, it was turned onto its front, 

the rivets holding the left, right and centre struts in place were all ground off 

and, for the first two, knocked through and the struts removed.  The remains of the rivets were ground flush

and then hammered out

after which the struts were cleaned up of all the old rust and muck and given a coat of primer.

The centre strut was a bit more difficult as it also had one of the water space baffles riveted to it which needed to be cut away before it could be taken out.  As the original access panel in the coal floor was only 14 inches square and it’s now frowned upon to use child labour, a larger panel was cut out so we could get in there with the plasma cutter.

The strut is now out but still needs the baffle holding rivets removed and a good cleaning.  It has been agreed that, for the new build, we will install two access panels and make them larger.  The rivets holding the bottom angle have been ground off

and the curved sections of beading have been removed, cleaned up and given a coat of primer.

The bolting up of the new panels has continued with the side panels bought in and attached 

followed by the curved rear section.

Next will be offering up the rear corner pieces to check for fit.

There has been little activity on Gervase this week as we are awaiting the return of the boiler but understand this is due to be delivered early next week.

Week Three

Tuesday saw the largest sections of 4253’s boiler cladding getting manoeuvred into position so they could be marked before getting taken down again for trimming.

Meanwhile, others continued with the dismantling of 5164’s bunker which involved grinding off yet more rivet heads

and, for the ducket section removed last week, knocking out the rivets holding the interior support brackets 

so they could be cleaned up and the rust removed before receiving a coat of primer along with the breather pipe which will be reused.

On Friday, the trimmed cladding sheets trimmed earlier were once again hoisted onto the boiler to check the fit

after which we started on the template for the ‘elephant’s ears’ being the corner pieces that will join the boiler and the front firebox cladding pieces.  More of the cladding bands were cut to length and the joining bracket ends cold riveted into place.

More rivets were ground off 5164’s bunker and all the new platework parts and brackets were laid out and the floor section moved into our workshop.

On Sunday, the top and bottom sections of the driver’s side firebox cladding sheets were welded together before being taken down again for the weld to be dressed and painted.

The steps were cut out of the fireman’s side of the bunker with the plasma cutter

and then carefully separated from the plate work as these will be reused.

The centre ‘T’ section of the ducket beading was too badly corroded to be reused so this was cut away and a new piece will need to be shaped, drilled and then welded to the underside of the beading.

We also laid a couple of girders on the workshop floor and positioned the new bunker floor plate on it followed by making a start on bolting various parts together to ensure the pre-drilled holes in plate and brackets are in the right place and everything aligns properly – so far, so good.

Week Two

No Update This Week

Week One

The week didn’t start well as we were clearing the yard in readiness for the removal of the 541 tender tank when we got a call to say the Hiab lorry had broken down so the tank’s departure has been delayed by a week. Accordingly, work was redirected to Gervase where the painting team finished the cab, including the floor, 

and undercoated the running plates.

Also, one of the lubricators was stripped down for cleaning.

Meanwhile, the cladding team were continuing with the firebox panels, measuring, 

cutting

and drilling the lower side sheets ready to be welded to the upper sheets at the weekend.

Come Sunday, they got welded together 

and then taken down again for the weld to be dressed.

On Gervase, the side and rear panels were rubbed down and given their first top coat

while the engine had all the valves ground in

and the gear wheel from the original exhaust camshaft was fettled to fit the camshaft from the spare engine which was in far better condition.

We were also advised that Gervase’s boiler passed its hydraulic test last week so, hopefully, will be with us soon for installation.