The before shot!  Lady Nan is seen outside the workshop having been shunted round from where she had been previously been stored. `Lady Nan` is eased into the workshop with the aid of the depot `shunter`
`Lady Nan` sits in the workshop awaiting the start of the overhaul. Lady Nan sits outside the workshop (in the pouring rain!) after the removal of the cab and saddle tank   Lady Nan`s boiler is lifted from the frames on the 23 March to be placed on a "lowmac" wagon. The boiler, well secured, sits on the lowmac ready to be pushed back into the shed for work to start. The frames are also lifted from the wheels to allow overhaul to take place ... and are placed on specially built rail mounted trolleys to allow moveability. Steve Masters gas axes the rivets holding the front tube plate of Lady Nan. Lady Nan`s Frames sit on the specially built trolley in the workshop A view inside the boiler of Lady Nan looking towards the firebox.  The long metal bars are the longitudinal stays that reach the full length of the boiler from the backhead to the front tubeplate.  This prevents damage (from pressure) to what would otherwise be unsupported areas of flat plate. Another look in the boiler Lady Nan`s tubeplate on the workshop bench This picture shows the boiler has been turned upside-down for easier access and with front boiler barrel section nearly ready for removal. The front section of the boiler barrel was found to be heavily wasted and it has been decided to replace this section completely. A selection of photos showing the "kit of parts" removed from Lady Nan for checking and overhaul. A selection of photos showing the "kit of parts" in a steam engine, which have been taken off to be checked and overhauled where necessary. The connecting rods sit on the paint bench in the workshop after a new coat of red paint. A shot of one of the cylinders and the frames, sat on its temporary trolley in the workshop. The front section of the barrel has now been removed. In addition all rivets have been removed from the foundation ring to enable it to be removed shortly. This has to be done as it was found that the outer wrapper plates of the firebox were grooved just above the foundation ring, a not uncommon fault that develops after time on many steam loco boilers. The lower sections, about 6", will be replaced with new plate that will be welded and re-riveted A view of the front section of the boiler barrel This photos show the upturned boiler firebox following removal of the foundation ring and lower 6 - 8" of the outer wrapper of the firebox. This was required as these plates were heavily grooved inside just above the foundation ring. The foundation ring. It is the rectangular device with the arrow chalked on it and pictured here upside-down.  Its function is to connect the inner and outer firebox at the base and act as a mounting for the ashpan.
Below is a picture of the grooving on the wrapper plates which resulted in them being removed.  The corrosion visible above the line of rivet holes and the slit on the curved end is not uncommon. The corrosion has eaten about 75% into the thickness of the plate demonstrating why it has to be replaced.
The refurbished foundation ring has been refitted to the copper firebox ready for the steel outer wrapper plates to be refitted to the outside This is a photo of the `former` used to flange the new throatplate and backhead plates. The 5 inch diameter steel bars were turned down from a wagon axle.
The plate is clamped in position, heated up and formed around the `former`. The plate is clamped in position, heated up and formed around the `former`. The backhead plate after flanging. The throatplate in position and tack welded to the original platework. The edges of the plate (where they wrap around the foundation ring) are feathered down to a sharp edge in order for the side sheets to overlap without a step. Dick Bellchambers, Lady Nan`s owner, works on the outer firebox sheet of Lady Nan Progress continues as these pictures show - In this case some of the eccentric straps, eccentric rods and horn ties have reached various stages of final painting One of the four longitudinal stays which tie the outer wrapper of firebox to smokebox tubeplate.  (These are shown in the boiler before removal in picture 13 & 14) A shot of the frames in various stages of undercoat.  Her final paint scheme will be as before her overhaul - blue with red frames/wheels This shot shows the left hand cylinder, slidebars and crosshead - the light blue is undercoat, but the final shade is yet to be decided  The wheels in primer This picture shows one of the four axlebox bearings. This one was heavily scored due to lack of lubrication and is being set-up on the milling machine for a skim, the journal on the axle has also received attention.
This and the following two photos show the progression of washout plug pads being applied to the front and back outer wrapper replacement plates. This shot shows the pad after having been formed around wrapper and then welded by coded welder. This photo shows the pad having been drilled in the radial drill which is then used to hold the tap steady and central. This is achieved by fitting a pointed centre tool in the drill chuck and locating this in a small conical hole on the top face of the tap. As the tap is turned to form the thread in the hole the centre tool is gently lowered by hand feeding the drill chuck. The drilling machine is only used to centre and stabilise the tap - not to drive it in any way. This shot shows the completed product with washout plug in place to test fit. The new boiler parts from Israel Newton arrived over the Bank Holiday weekend. The new barrel piece will form the front section of the boiler (see picture 14 giving the 'before' shot) and also the smokebox as was previously the case.  The smoke box was cut off to ease boiler stripping and before it was known that barrel section also needed replacing. The picture on the left shows the new front tubeplate.  It has been been flanged but not yet drilled.  The right hand picture shows what it will look like after drilling - this is a picture of the old tubeplate. This drawing shows the drilling dimensions for the new front tubeplate The new longitudinal stays for the boiler were collected at the weekend complete with copper washers and nuts.  There are 4 of these in the boiler weighing approximatley 1 CWT (hundredweight or approx 51kg).  The end with the single nut is threaded into the boiler backhead and lock nutted whilst the other end has two nuts and washer either side of smokebox tubeplate. This picture shows in more detail the smokebox tubeplate end of the longitudinal stay. The six items are large and small nuts and copper washers for the longitudinal stays.  Bottom right is a copper stay used to join the inner and outer firebox plates, thus the two threads.  On the left is a patch screw that will be used on the replaced plates on the firebox outer wrapper in lieu of rivets.  This is because one end is inaccessible with this kind of repair and so a rivet head can not be formed. Following the arrival last month of the front tubeplate, work has begun on drilling the holes.  The tubeplate is seen on the workshop drill having the pilot holes drilled by Paul Ebsworth. A copy of the boiler drawing for Lady Nan The attached picture shows the tubeplate vertically mounted on the pillar drill in a jig and a start made on drilling the 56 pilot holes around the flange of the tubeplate to allow it to be riveted to the smokebox.     Possibly the last picture of the tubeplate prior to it being fitted in boiler barrel. The hole for main steam pipe has been cut and surrounding fixing stud holes drilled and tapped. You can also see pilot holes around the flange This picture is taken during installation of the sling stays, these are the flat plates held top and bottom by new steel pins and split pins. We have now brought the new section of boiler barrel into the workshop and have made a start on preparing it for fitting. This mainly consists of grinding the seam weld (the barrel is formed from a flat plate, rolled to a cylinder with the join being welded) flush to enable the fitting of the new tubeplate and also where it fits and overlaps the rear barrel section.
Work on the 19 October focused on the trial fitting of the new boiler/smokebox section into the smokebox saddle. The reason being because the new part has a marginally bigger diameter than the old one that it is replacing. The trial has shown that we need to ease the saddle a little before it will sit properly.  The above picture is taken mid way through the trial. On Sunday 30 October, Lady Nan was re-wheeled.  Present to watch the excitement were a contingent of 'Ganger's' (L-R; Rory, Alex, Aaron, Chris, Barney) all of whom who have assisted in the overhaul. Keith Nicklen stands beside Lady Nan's frames with the front wheels located underneath and awaiting the rear wheels to be put in place.  The temporary trollies which supported the frames (seen in picture 8) have been removed and the frames are supported on jacks and steel supports allowing the wheels to be rolled underneath The rear set of wheels sit in the workshop prior to being placed in position Steve Masters adjusts one of the jacks With both sets of wheels in position the frames are almost ready to be lowered over the axleboxes. Aaron reaches for the paint to start touching up the frames. New recruit Andy gets stuck in on his first day, having become 'hooked' following his participation in a recent footplate experience course.  He is shown guiding the axleboxes as the frames are lowered. All Done! The re-wheeled frames sit in the workshop. Next job - the boiler...  Following an abortive first attempt the replacement wrapper plates were finally welded into place over the course of the last two days. Yesterday the longer front and back plates were done and the two straight side plates were completed today by Bennett Boilers of Highbridge. This shot shot shows plates as at the end of the 14 November 2005 This shot shows the finished job. The white deposits visible on the plates is due to the flux on the welding rods.
 
Dick Bellchambers writes:- Now that the welding of the new wrapper plates on the fire box is complete [Dec 05] we are starting to make progress with the other fixings. The picture shows the use of patch screws. The two top ones go into the corner of the foundation ring. Because of the tight corner the geometry does not allow for the use of rivets. The other three in a vertical line are in place of rivets and are required to fix side plate to the back plate. Originally rivets would have been used but because the inner firebox is still in place it is not possible to get at the other face of the outer firebox to enable a rivet to be formed. The hexagon heads are used to tighten the screws and are then removed (this has been done on the bottom one in the picture). The heads are then tooled to form a watertight seal.
This wednesday's task (21 Dec 2005) was to rivet the Firehole and Boiler Barrel.  This picture shows the temporary forge used to heat the rivets to nearly white hot Rory takes the hot rivet from the forge and inserts it into the hole from the inside of the firebox (using tongs!).  Paul is inside the firebox with the 'holding on' tool ready to put it onto the rivet to support it while the other end is rivetted over. Steve Masters rivets the end over to form the head THe completed rivest around the firehole ready for final tooling. Ditto for the barrel. This picture shows the coupling, connecting rods and valve gear (between frames so not visible in pic) have been replaced to enable the valve timing to be set.  The frames are pictured outside the workshop. Over the weekend (7/8 January) the boiler was rolled so that it is now upright to enable progress with riveting of the new barrel piece. Following recent inspection it was decided to replace all the crown stays as they would not have lasted until the next full overhaul. Work started today on removing the old ones.
The ssequence of six photos follows through the process of riveting of the new boiler piece.  This first photo shows Rory Edwards as he prepares to pick up the almost white-hot rivet from the forge and place into the correct hole in the barrel. Whilst the rivet is being placed, Jerry West heats up the next rivet while twins Chris and Alex Hopkins steady a sleeper on which ESR Locomotive Superintendent Steve Masters stands on while forming the head on the rivets. This shot shows the placing of the hot rivet.  Rory is shown going into the boiler barell to place the rivet in the hole. This is done as quickly as possible so that the rivet is still white hot when Steve Masters begins forming the head from the outside of the barrel. In this picture, workshop volunteer Nick Adlam, who is actually 6ft 5, drew the short straw and was crammed into the boiler of Lady Nan to control the other rivet gun.  This gun is used to keep the rivet in the hole while the other head is formed on the outside of the boiler. THe process then repeats with Steve Masters (wearing green ear-defenders) and Rory Edwards (holding the tongs) wait patiently for the next rivet to be heated up by Jerry West.  In the background, one of the twins and Graham Watters get ready to hold the sleeper, that Steve will stand on whilst forming the rivet head, steady from excessive movement. Rory heads for the inside of the boiler with another rivet As earlier photos mentioned, it has been decided that the crown stays should be replaced. This view taken from above the firebox shows the 24 holes following removal of the old stays. Pieces still remain to be removed from the crown of the inner firebox. When this is complete the holes will be cleaned up and retapped to a slightly larger size ready for the new stays to be inserted. Long time no photos says Dick Bellchambers.  As of the 22 Feb 2006 riveting has been completed around nearly half of the foundation ring. The photo shows the throat plate. Hanging from the sky-hook is the pneumatic holder-on which is used to hold the preformed head of the rivet during the process to form the other head which are the ones that can be seen here. The holder-on is being supported from the overhead gantry due to its considerable weight. The other photo shows some of the new crown stays prior to fitting. As a result of the round topped nature of the boiler over the firebox, stays of three different lengths are required. Nuts and copper washers, shown here on one stay, are fitted to the protruding thread of the stay in the firebox to protect the end of the stay from burning in the intense heat. If they waste too much in use they would need to be replaced.
This picture shows Paul Ebsworth caulking rivet heads in the firebox. It also shows the new rivets in the foundation ring, new copper stays ready for riveting and some new crown stays with nuts on at the back. Lady Nan`s owner, Dick Bellchambers is shown here caulking the barrel joint (where the new barrel piece is rivetted to the existing) to make it water tight This shot shows Rory Edwards tapping one of the holes for the crown stays. It should be noted that over half of the tap is already inside the boiler. It needs to be so long as it has to create what will be a continuous thread in both the outer wrapper and also the top or crown of the inner firebox. (Samples of the new crown stays are shown in photo 78).
Lady Nan`s frames and boiler out on the `back road` in the morning sun(!?) as part of the shunting taking place for the Spring Steam Gala Nan`s cab and saddle tank, soon to be taken into the workshop for overhaul. Recent progress has concentrated on the crown stays which are now all installed. This picture, taken from inside the barrel, shows the new stays between outer wrapper and firebox crown. This picture was taken before reinstallation of sling stays that had to be removed to ease installation of the crown stays (see picture 50). The Sling stays have now been re-fitted. This picture shows the external view of the outer wrapper. 12 stays have been riveted and the most recently fitted have yet to be so treated. Riveting of the foundation ring has also been completed and we will shortly be submitting the boiler to the inspector for his approval of internal work and for his agreement to installation of the new front tube-plate (see picture 49) after which it will be impossible to gain access inside the boiler. Work continues on `Nan` over Easter as this photo shows.  The throat plate and foundation ring with all riveting and caulking (closing of the gaps between plates etc. ) around the foundation ring is now completed. The boiler had been dragged out of the workshop so that it could be returned to its proper upright position.
Inside, work has started on the saddle tank.  The top remains in its curent condition... ... but the underside has been primed and undercoated. Work continues to progress with Lady Nan and in late May, the new front tubeplate was inserted into the boiler.  These two photos show Paul Ebsworth starting to drill holes for the rivets. .. and by the end of the day about half of them had been done between Dick and Paul Dick Bellchambers writes: "It was decided that new water level gauges should be obtained as the old ones were very worn. They were test fitted today. The one on the right is the complete assembly with protector in place and that on the left has the protector removed to show the glass tube which will show the water level."
A view looking down into the dome showing the regulator valve which was fitted today (8 August) A view of the smoke box showing the steam pipe fitted and rigged for its hydraulic test, which was successful Another view of the firebox end of boiler showing the newly fitted regulator stuffing box (the brassy looking fitting near the top).
A picture of the tubes that have arrived to go inside Lady Nan`s boiler This picture shows the first trial tube inserted in the boiler, shown in the centre of the photo.  Unfortunatley the end that fits in the smokebox tubeplate was slightly over-size which has nessecitated opening out the holes slightly , a task now all done. A view of the smokebox end of the boiler of Lady Nan with the tubes fitted, expanded and beaded.  The same at the firebox end... The picture shows locomotive owner Dick Bellchambers about to place a warming fire in Lady Nan for the first time since 1998.          The Fire burns brightly...  The gauge glasses are covered to stop them getting dirty from the smoke coming out the fire hole Smoke! Elsewhere the initial fit of the vacuum system was taking place. It was decided to redesign the routing of the main vacuum pipe which was never fitted prior to the locos preservation.
Dick Bellchambers writes:- The fire is glowing on the grate, the pressure gauge is showing nearly full pressure and the safety valves are feathering in this photo of one of our in house trials before it is presented to the boiler inspector on 13 November. Happy to report that this steaming was successful. On Wednesday 6 December, Lady Nan`s boiler was lifted from the `lowmac` wagon that had been its home for nearly 20 months and returned to its frames. Brian Laitt guides the boiler into frames whilst Steve Masters and Keith Nicklin look on. The three then check final adjustment as the boiler i splaced in the frames. The boiler re-united with the frames now means that final re-assembly can commence. Having completed the lagging of the boiler the saddle tank has now been fitted. Progress is also being made with the fitting of the various cab fittings. Out of sight the cab and bunkers have been prepared for fitting and painting.  The workshop is fairly crowded at the moment. One of the Rolls Royce/Sentinels is being painted" 30075, the Yankee Tank is in for new design grate to be fitted and of course 1719, Lady Nan` continues in residence.
 
A view of Lady Nan outside the workshop today to enable 30075 to be removed from workshop following installation of its new grate. On Lady Nan much of the pipework has now been fitted. The tank has been partially filled to check for and correct leaks at the water take off valves and injectors. The cab and bunkers are being readied for fitting in the near future.
What a difference three weeks make!  A now complete Lady Nan runs under her own power for the first time since 1998.  Volunteers on the footplate as Lady Nan sits on `1` Road by the foot crossing Lady Nan sits on `1` Road at the Depot Lady Nan, freshly lined out sits in the workshop Lady Nan is nearly there! Posing outside the shed with only minor details still to complete,  she will be presented to the boiler inspector on the 4th April. Dick Bellchambers writes: "I am pleased to report that loco 1719 `Lady Nan` successfully passed her examination by the boiler inspector today following a two year overhaul at ESR, Cranmore. She will commence duties on Good Friday undertaking the `Drive for a Fiver` duties that until now were performed by sister loco 1398 `Lord Fisher`. Lady Nan sits on `1` Road by the foot crossing waiting for her first `Driver for a Fiver` passengers on Easter Saturday. In fact no time was wasted in getting `Nan` back into the thick of the railway action.  This shot was taken during a spot of light shunting on the Saturday evening with Locomotive Superintendent (and the leader of Lady Nan`s restoration team) Steve Masters at the regulator. The tail lamp...  Lady Nan sits by the new up home bracket signal awaiting 30075 (asissting in the shunting) before returning to shed and disposing.  With this shot comes the end of this Gallery.