2011/12 10 Year Boiler Overhaul
The 10 year boiler overhaul for 5542 is due to commence on Monday October 3rd 2011 (Day 1)
This page will give regular updates of the work undertaken ,with photographs if available, at the South Devon Railway
Buckfastleigh workshops in our attempt to complete the work by 20th March 2012(Day 168)
Preparation work prior to 03/10/2011 will show as minus(-) days, days after 03/10/2011 will show as plus (+)days.
These pages are now being visited by record numbers of interested supporters (over 700 in one day recently)
and we thank everyone for their ongoing interest and support
Saturday 18th February 2012 Day +137. 10 workers today and we are at last well into the retubing process which got
underway in earnest late last week. Well over half the 196 tubes are now resting in place in the boiler following preparation
swaging to both ends using the recently installed machinery which is both simple and efficient in its process. Tubes are reduced
by 2-3 mm at the firebox end by forcing a collar arrangement over the tube end and expanded by a similar amount at the smokebox
end by forcing a solid former into the tube end by about 300mm. Other work concentrated on producing a Crinolin 'cage' arrangement
for the top half of the parallell boiler section to help support the cladding in that area and avoid the risk of damage when it is walked
on during cleaning and tank filling operations. Other work underway is the modification of the ashpan and mounting arrangements to
the bottom of the boiler. The new design will allow for easier disposal of the locomotive at end of daily service, and also further reduce
the risk of dropping hot ash during normal operation. Work completed during recent days included fitting of the new stainless steel
delivery trays in the boiler, despatch of the tanks and bunker for sand blasting prior to re spray. This work should be completed within
about 3 weeks. Further work on the new Auto Gear assembly has also been progressed along with the mid week paint gang work on
and around the frames .Our 'new' Stones Generator has also been delivered .
L&R) Mr and Mrs Dunse engaged on tube preparation C) Some of the 'Fruits of their labours'
L) Swaging machine showing expanding former C) New Water Feed Trays fitted to roof of boiler R) Over 100 tubes in place awaiting expansion
L) Ashpan modification underway C) Rear Door removed R) Mounting brackets being modified
For 4 images from 18/02/2012 by Mike Dunse click here here here and here
Saturday 4th February 2012 Day +123 9 participants involved in the action today and things are now begininning to enter the
preparation for refitting the boiler stage. Attention mainly on the frames with serious cleaning and touching up of paintwork
underway along with sorting and cleaning of parts , nuts and bolts that will be required during reassembly work. Preparation of
bunker and tanks for transportation to the paint shops was also underway. Boiler welding repairs to small cracks discovered
during inspection along with small areas of building up have also been taking place during the week just passed, along with
delivery of the new valve ring assemblies .
L+C) Two small lengths of weld required on the boiler barrel R) New Valve ring assemblies
L) Ian Aldridge gets serious about the paintwork C) Ian and Jennie Dunse about to go 'Head to Head R) Room for one more in there?
Saturday 28th January 2012 Day +116 Today saw 8 active workers at Buckfastleigh and the current situation finds us with
all the driving wheels now checked and refitted, with no work required on any. We are replacing the axle box lubrication pads all round.
The pony wheelsets are yet to complete although they are prepared for inspection and are not expected to reveal any problems. Last
week saw rivetting work undertaken in various areas and eventually we have taken the opportunity to replace a few more than originally
planned (approx 60 in total) because some of the remaining ex B.R. (possibly GWR) ones that we first took out were definately showing
more signs of wear and tear than we expected which then warranted further investigation and replacement. This probably was responsible
for some 'chattering' at the point where cab and tanks met. Many of the removed components are receiving general cleaning to allow
for easier reassembly when required. The replacement piston and valve components are all understood to be progressing via outside
contractors to schedule. Some small modifications to the bunker have also been completed
L) Center Drivers replaced R) Riveting Frame Stretchers
L) Frame Stretcher Riveting R) Bunker modifications underway
Boiler Work News.
A range of new administrative requirements during major boiler overhauls has delayed progress a little since the New Year .
This means that we now find ourselves playing 'catchup' and are currently 2-3 weeks behind our original schedule. (those
approaching a '10 year' overhaul take note) However this does not mean that we have made no progress in this area and apart
from receiving the formal go ahead from our boiler inspector this for all remaining work up to the hydraulic test , today has seen
much stay work activity. The new copper stay work on the front plate has been completed today , along with much of the steel
stay work. Final measurements of boiler barrel plate work has revealed just a few small areas that we will build up for 'good
measure' with the tapered section actually, despite our reservations pre stripping, being in very good condition, especially as it
is now at least 50 years old. The pictures below will show large areas of white 'crack test' paint which has shown no plate work / stay
area cracking and just a very small section of cracked weld which can be very easily rectified. The internal corners of the firebox
are also in fine fettle.
L) New Stays in place ready for attention C) The old plate R) Waterspace showing new stays Copper lower , Steel above
L) New mudhole doorway showing copper and steel stays C) Inside firebox R) Outerwork completed
Inside firebox Copper stays completed , stay nuts being fitted
Saturday 21st January 2012 Day +109 Brief update. Centre driving wheels now checked , Bunker removed
ready for repaint work. Full update with pictures next Weekend
Sunday 8th January 2012 Day +96 Happy New Year to all our 'visitors'
A new Year 'catch up' with progress at Buckastleigh reveals that despite the recent break for the festive season progress
continues both in the boiler shop and on the routine work on the frames and wheels. The replacement plate on the firebox
outer wrapper is progressing well and we shall soon be starting the retubing work. Needlegunning work on the boiler barrel
continues during our visits with attention now on the boiler barrel . Having now inverted the boiler to allow the riveting
and replacement stay work to progress, descaling of the underside is much easier. I'm pleased that we only have a relatively
small boiler! In the main workshop full use is being made of the wheel drop facility to check out the axleboxes and journals
as it is now 5 years since the retyring work was done. We are pleased to report that having completed 2 of the 3 driving wheelsets
no undue wear or damage has been found and the modifications to axlebox lubrication made during restoration have proven
100% sucessful. Whilst the centre drivers are out of the frames we shall be replacing a few rivets that have worn a little loose over
the years on the frame stretchers. This work should be completed this week so the last driving wheelset can be checked out and
the frames made ready to receive the boiler once again. We are pleased that work continues on schedule and on budget at present,
and having recently secured an 'underwriter' we will be progressing the repaint work on tanks and bunker in the next few weeks.
Let the livery debate begin!
L) Foundation ring rivets inside firebox C) Close up of internal firebox rivets R) Outside Foundation Ring Riveting almost complete
L) John Castle whose only escape is to leave the country (so he is) C) Centre drivers checked over and ready to refit R) The next 'greasy bit' for attention
L) Father and Son discuss Eccentrics C ) Journal looking good D) Someone knows how it all works!
Images copyright M Dunse and J Wood.
Sunday 11th December Day +68 Work on the boiler has concentrated on reconstruction of the smokebox with handrails
and internal bracket etc being fitted. The endless needlegunning work continues when we have volunteer labour available
with Saturdays work concentrating on the top sections . The top mudhole doors have been completed with the doors trial
fitted. The 'Bottle Ends' for superheater flues have now been manufactured and 200 small tubes have been delivered as part
of a 'lot' to cover the SDR's needs for the rest of the winter. Some of the injector pipework has been removed for minor
modification and the Chimney, blower ring and petticoat pipe assembly have been separated ready for checking and refitting.
Bearings for the Auto Gear have arrived so work can continue in that area as and when time allows. The next major work will
involve dropping the wheelsets to check that all is well, but we are not expecting to need any major work in that area.
L) Boiler backhead showing dressed fitting surfaces C) Smokebox with handrails and internal brackets R) Right side locking bar hinge
L) Needlegunning continues C) Bottle ends for Superheaters R) Chimney and Blower ring separated ready for checking
Four people required to 'Look into' it' and another to take the picture, its a wonder we get anything done.
And you can tell who 'worries' most about it
Copyright 5542 Ltd
Monday 28th November Day +55 (about a third of the way through the project)Boiler work has continued with the new plate on the firebox front now
prepared and welded in place ready for staying and riveting to take place. The top mudhole doors have received attention to return them to
good condition and work on the new smokebox has continued with internal brackets fitted and the door also trial fitted, it has also been
offered to the boiler to confirm correct fitting and alignment. We are well on target to commence tube replacement before Christmas. The
overhaul of boiler fittings continues steadily as and when time allows, and all backhead faces have now been cleaned and refurbished as nessecary.
On the frames some of the riveting has now been taking place along with sandbox refurbishment. More pictures to be added
L) New boiler plate in place C) New smokebox with door trial fitted R) Selected frame re-riveting is underway
Images Copyright Locomotive 5542 Ltd
Sunday 20th November Day +47 Work is now really moving on apace. The boring work is now completed on cylinders and valves
with a complete set of valves and pistons now being manufactured. Work on the boiler itself is now also in full swing with the area of plate for
replacement now removed and preparation work on the new piece underway . Work on overhaul of fittings continues, along with Auto gear work.
Sadly no pictures to support the above information at this time, but they will be added as soon as available
Sunday 13th November Day +40 Yesterdays' work continued the needlegunning preparation for the main boiler work to begin.
The boiler internal trays and associated brackets have been removed to make access a little easier. An informal visit from the boiler inspector on Thursday
last continues to reassure us that there will only be limited major work and also confirmed the crown stays to be in good condition requiring no major
work, with just some nuts being replaced. Design and preparation of the rodding runs for the front end Auto gear continue along with work on cladding
components to allow easier fitting during reassembly. Work on the cylinder rebore is now complete with attention to the valves being undertaken later this week.
L) The 'Needlegun Team' continue their work C) Fountain seat showing the weld that caused us problems 10 years ago R) Crown Stays in the waterspace towards the backhead
Sunday 6th November Day +33 Yesterday's update visit to the S.D.R Engineering found our boiler having reveived its first
serious attentions of the engineering staff by way of boiler plate thickness measurement concentrating on the backhead platework and
crack testing of B.R. welding on the boiler barrel joints. All of the above resulted in our continued good fortune and no excessive
wear or cracked welds found to date. The foundation ring is also very good with no grooving found. The main steam pipe has been
removed and one of the more undernourished members of the workshop staff has managed to squeeze between the lodgitudanal stays
to get a close up view of the only other major unknown factor at present namely the Crown Stays, but even these look in reasonable
condition at first sight. We now keanly await the boiler inspector's visit later this week for confirmation of the boiler work program.
Other work has included stud removal on Superheater header and Fountain.
L) Boiler showing crack test paint on barrel seams R ) Boiler internal with Main steam pipe removed
L) Foundation ring looking across front front of firebocx L) Firebox side stays R) Crown Stays from inside of firebox
Above images Copyright John Wood
Saturday 29th Oct ober Day +25. 6 workers today shared their attentions between needle gunning the boiler and planning the
fitting of the front end Auto gear. Attention on the boiler concentrated on cleaning up the vunerable areas so that those required
to confirm what work is going to be required can get the clearest possible indication of the current condition. We are optomistic
that we will have a full picture of required work in 7-10 days time. The new smokebox door was also available for inspection
Firebox tubeplate Internal view of boiler barrel looking towards firebox New smokebox door under manufacture
Above images Copyright John Wood
Boiler Work underway Auto Gear Route Planning Frames bereft of boiler
Above images Copyright Mike Dunse
Thursday 27th October Day +23 A visit to Buckfastleigh today revealed the boiler now removed from the frames with all tubes and flues removed,
along with all boiler fittings and associated studs. At first look the unclad boiler shows no obvious unforeseen problems, and the work that will be required
is generally no worse than we had planned for. Final confirmation and a work list will be drawn up once the boiler has had the attentions of the ‘needle gun team’
who will start work on Saturday(29th). Overhaul of the boiler fittings is now also underway with several already completed. New superheater element ends
have been delivered to replace those fitted 10 years ago with the intention of them completing 2/3 years at best. We are pleased to report that 95% of the boiler
cladding is fit for further service and with the luxury of being able to work with the boiler out of the frames the few replacement and modified parts will be much
easier to manufacture than first time around. The lubrication regime we instigated mid way through the last 10 years has also paid dividends with valves and
regulator now receiving ‘just the right’ amount of lubrication and are therefore in excellent condition. Who says you can’t teach steam loco drivers new tricks!
The valve and piston liners will receive some routine attention during the next few weeks. We will take the opportunity of replacing a few loose rivets in some of
the frame stretchers whilst the boiler is absent along with replacing some bolts that were used due to restricted access issues when the frame
repair was completed 5 years ago. Finally, a quick 'Thank -you' to Mr Bridger for the kind donation.
Boiler Lift Images Day +22 Above Copyright R Lee
Below copyright J Wood
Front tubeplate with tubes removed Boiler awaits smokebox removal , all studs removed prior to moving to boilershop New Superheater element header ends
Friday 21st October Day +17 It's 7 days since the last update and although I'm not fully up to date as yet
work has continued to progress apace with the smokebox now fully dismantled , all steam pipes removed
and the chimney cut out (O.K. as the smokebox is being replaced). Main flue tubes also removed along
with sundry other work on dismantled tanks and cladding
All Images copyright Peter Darke
Friday 14th October Day +12. Cladding and boiler barrel insulation removed today,
and so far no 'nasty' surprises revealed as yet. Sadly no pictures today(now added). Next update in
about a week when there should be more progress to report. Original red oxide paint is still visible on boiler barrel
Boiler insulation and backhead cladding being removed Copyright John Wood
Wednesday 12th October Day +10. Tanks and Cab roof removed today
All images copyright Peter Darke
Friday 7th October Day +5 More boiler backhead fittings removed along with piston removed ready for cylinder skimming
(L) Boiler backhead (C) Piston removed (R) Cylinder ready for 'skimming'
( Copyright Mike Dunse)
Wednesday 5th October Day +3 All the smokebox end bolts are now removed along with steam pipe cladding. Tank
and Bunker nuts loosened. More cab fittings have been removed along with fire grate and brick arch
(Left) The old smokebox beginning to look devoid of fittings. (Right) Mike Dunse take a 'breather' to admire the fruits of his labours (John Wood)
Tuesday 4th October Day +2 Work acheived so far includes removal of smokebox door
and all associated hinges brackets etc. Removal of some boiler fittings.
Old Smokebox door inner skin(left) and outer skin (right)
The soot inside the door might have been there since the late 1950's or even earlier
New smokebox awaiting fitting of recovered 'furniture' from the old one (John Wood)
Sunday 2nd October Day -1 Loco dispatched to Buckfastleigh for overhaul to commence.
Thursday 16th June 2011 Day -76 New smokebox blank delivered to Buckfastleigh.