5637`s 10 year overhaul has now started and it can be seen here with the cab, tanks and smokebox fittings removed. Another view with the tanks removed. The tanks are stored in the yard awaiting attention. The superheater elements can be seen in front. Steve Masters sits in the smokebox waiting for the next tube to be knocked out by Barney and Alex from the firebox. The chimney, steam pipes, superheater header and elements and blast pipe have all been removed. A view looking into the boiler from the smokebox through the front tubeplate. One superheater flue has been removed (the others can be seen each side), below are the small tubes with the longitudinal stays above. The firebox tubeplate can be seen at the back. 5637 in the running shed with all of the lagging removed from the boiler and some more of the 218 boiler tubes knocked out waiting to be carried away. A view in the firebox showing the tubes. The upper rows have had the tubes removed, the middle section have had the tube beadings cut off and slit ready for removing and the lower tubes are still in place. A small wood fire was lit inside the Blast Pipe to burn out the hardened oil deposits. The white vapour is from the oil burning within the ports normally under the jumper ring. Having burnt out the oil from the inside of the Blast Pipe, Daniel needleguns the jumper ring to remove all of the scale. With the cab wooden floor boards and steel panel removed, the top of the vacuum brake cylinder is exposed. Brian Laitt holds the brass number plate in position while Paul Ebsworth removes the nuts from within the bunker. With all of the tubes and flues removed, the front tubeplate rivets were being burnt out. As the smokebox needs to be renewed, the top section was removed to make things more comfortable working in there. Steve Masters cuts out the last of the front tubeplate rivets as Steve Searle waits before going into the smokebox to knock them out. With 5637 now in the workshop, the front tubeplate was removed. Another view of the boiler with the tubeplate removed and lying in the smokebox. At the back of the boiler can be seen the firebox with the crown stays above. With access to the inside of the boiler made much easier, having removed the front tubeplate, a closer inspection of the firebox and stays could be done. Seen here are the `Crown Stays` running vertically, `Transverse Stays` running horizontally and the main steam pipe with the steam collector pipes positioned right at the top of the boiler. A spring hanger assembly from 5637 after being cleaned up ready for inspection. Jeff builds up some localised pitting in the bottom of the boiler barrel with weld. Two cranes were hired to lift the boiler out of the frames and to lift the frames off the wheels. Two cranes were used rather than just one as the boiler was needed to be rolled over and while one crane started to turn the boiler, the other supported it to ensure the whole operation was under full control. The boiler removed from the frames was temporarily sat on the ground before rolling it over. Part way through the boiler lift, the boiler was carefully rolled upside down before being place onto a wagon. The frames minus the wheels now sits in the workshop. The boiler having been turned up side down, is now sat on a wagon, where work can commence on the plate work around the foundation ring. A view looking at the foundation ring (normally at the bottom of the boiler). Note some of the rivets have been removed. The front bufferbeam is lowered to the ground by Alex. With the bufferbeam removed, James gets to work needlegunning and chipping off the thick rust now exposed. The wasted platework around the foundation ring has been cut away for renewal. The lower part of the backhead had grooving on the water side as well as general wastage on the outside resulting in the plate being considered too thin. The bunker was heavily patched in BR days and the plate work is now very thin in places. The left hand side has been cut away before new steel plates are formed and fitted. With the help of Roger`s hydraulic jacks, the foundation ring was eased off the firebox. Steve and Chris remove the vac pump from inside the frames. Work then started on cleaning and stripping the vac pump for inspection. All of the axleboxes have now been removed and cleaned before the white metal bearings are melted out and renewed. The firebox lap seam rivets are being replaced with copper patchscrews as the steel rivet heads have wasted away over time. Firstly the rivet is burnt out and then the hole is reamed, tapped and countersunk as shown here with Paul using the countersinking tool. The tool is guided on a shaft screwed into the hole to keep it concentric. The patchscrews are screwed into the holes and tightened until the square head shears off. These screws will then need final tooling down of the edges to make them water tight. The 30" diameter piston from the Vacuum Brake assembly has had a new rubber ring fitted as the last one was worn. The overhauled vacuum brake cylinder has been reassembled and is now waiting for a modification to the gland and final painting before refitting. The Vacuum Reservoir has been refitted inside the frames. Note the red paint progressing forward from the rear as the frames are needlegunned and inspected. A view showing the extent of the pitting inside the frames under the cab floor and bunker. Most of the deterioration is likely to have occured during its time in Barry. The curved members are the radial truck guides. Steve Searle melts out the old white metal from the big end shells. Chris needleguns the foundation ring. The studs seen here are for attaching the ashpan and for the firebar bearers and will all be replaced. The edges of the foundation ring are locally built up with weld and dressed back to give a clean square edge. Paul Ebsworth has made a set of `Hornguide alignment tools` in his home workshop delivered here in a specially made box with a Great Western Railway notice on the front. With the lid removed, the tool can be seen. They are designed to stretch across the hornguides and the central bobbin adjusted to guide a datum bar to represent the axle centre. All should become clearer in later pictures when we come to use them. The valves have been removed and are in the process of being cleaned and inspected. With all of the motion removed, the insides of the frames are being cleaned before needlegunning and painting. The gloss red paint is gradually working forward inside the frames and here the overhauled vacuum brake cylinder has been refitted and awaits final painting on the top. One of the radial axlebox bearings after remetalling and machining. The thrust faces have also been white metalled on the radial axlebox bearings. James drills out the screws on the axleboxes which hold the bronze liners in place. They will be refitted with shims and then machined to suit the horn gap in the frames. The front bufferbeam and dragbox has been finished. The frames have now been needlegunned and fully painted. Parts of the motion have been overhauled and refitted. The backhead has had two slots cut out to eliminate the cracking found around the outer column of stays. This has also given access to the inside of the back corners where some grooving has been built up with weld. A view looking down the water space showing the cut out in the backhead and the weld repair. Note the boiler is up side down so this view would normally be seen from the foundation ring looking up. The job of measuring the hornguides and axleboxes has been started. Here Rory supports the end of the measuring micrometer to set the rear axle datum the correct distance from the driving axle datum. The throatplate slots completed. These slots cut out in the plate remove the cracks found around the outer column of stays. The slots in the backhead ready for the new plate to be cut to fit. The new section of steel is cut to shape and tried for size. There is an equal gap all the way round which forms the weld prep. The bunker has been turned over and the base needlegunned, repaired and painted. With the bunker turned back up the correct way, the plate work is painted. Grant Bolton working on the lathe machining rivets for the axlebox bronze liners. The finished rivets. The replacement steel sections for the backhead and throatplate are formed around formers to match the profile of the existing plate. Here the plate is heated before being bent round the former. With the steel glowing red, the plate is bent round the former. The completed bend. Using the large heating nozzle got the oxygen regulator rather cold! The backhead section sat in position. A view inside the water space showing the matching bends of the new and old plate. The ends of the boiler plate are roughly machined to taper out to a knife edge along the foundation ring. this is to allow the side plate to sit on the outside face without a step from the inner plate stopping. The front section in place for a trial fit. The foundation ring has been refitted onto the firebox and the new backhead section has been trial fitted. The chalk marks indicate where it was to be heated to adjust the bends to fit the foundation ring perfectly. The replacement throatplate section has now had the three mudholes cut out. Work has restarted on the bunker with the new steelwork being tacked in position. We were able to reuse the complex curved plate from the original bunker which saved having to remake it. Here Dave is inside the bunker welding it in position. Chris Hopkins drills the holes for the foundation ring rivets in the new section of steel backhead. The weld prep` has been ground on the backhead and the new blowdown boss has been made and welded in position. The welding on the boiler is now complete and work has started fitting the corner screws into the foundation ring. The throatplate with the completed weld. The corner screw holes being drilled out. The drill is braced using Paul`s fabricated bracket supported on long studs fixed in foundation ring holes. The repaired crank axle and wheels are now receiving top coat after being needlegunned, primed and undercoated. The new bunker is nearing completion with the rivet holes being drilled. The new boiler plate is drilled ready to fit the corner screws into the foundation ring. The corner screws fitted along with the lap seam patch screws. The first of many foundation ring rivets have now been completed. The `Flat-Pack` ashpan has been tack welded together ready for a trial fit while the boiler is still upside down. Alex Hopkins heats the rivets using the oxy propane torch. With the rivet in the hole, the two rivet guns do their work. Another one of the couple of hundred rivets in the foundation ring is completed. Incidently, ear plugs are being worn as the noise is deafening. Videos of the riveting can be found at http://www.youtube.com/watch?v=VAArP6swIuY All six axleboxes have now had the bronze liners shimmed and machined to a fine tolerance and each box has been trial fitted into the hornguides which have also been trued up square, flat and parallel. The next job on the axleboxes is the remetaling of the thrust faces and crowns. Here the former is held in place with one or two G-Clamps and sealed with fire clay before heating and pouring the white metal. A video showing the axleboxes being machine can be found at http://www.youtube.com/watch?v=Ur4j-e80ofM Wednesday 27th May was the day of the big lift to turn the boiler, rewheel the frames and fit the new bunker. Here the boiler has been carefully rolled onto its side before returning upright. The boiler now upright on the wagon. Temporarily stored out of the way until the rest of the lifts were complete. The wheels were positioned in roughly the right place before the frames were lifted. The frames lifted off their temporary trolleys. The frames almost in position. The final decent over the axleboxes. Ralph moves the trolleys out of the way now that they have done their job. The bunker is then lifted into place. The bunker finally down on the frames. Some of the gang who spent all morning in the rain! Chris, Alex and Dick tap the holes for the new crown stays. All of the 160 crown stays have now been fitted and are ready to be caulked. A view of the top of the boiler showing the new crown stays. Geoff polishes the coupling rods before the bushes are pressed in. One of the crossheads is machined. The running surfaces have been white metaled and careful measurements have been taken to give correct clearances between the slide bars. The crosshead is shown on the milling machine upside down. The new die blocks are nearly finished with final fitting ensuring equal clearance along the link. The die blocks curved profile was machined as a series of short flats and then filed by hand to fit the slot. The results are very successful giving a good close fit. A view inside the frames, now with both pistons, crossheads and slidebars fitted and one expansion link. The vacuum pump had severe pitting in the bore from the corrosive atmosphere at Barry scrapyard. Here the pump body is set up on a horizontal borer where it is machined larger to restore the bore. Dave Golden-Hann fabricates a new balance pipe to go between the bunker and the left hand water tank. The original cast one is bolted below to act as a jig. The right hand tank is now in position on the frames enabling oil pipe runs to be made and it is also required to hold the reverser for valve timing. Space has become available in the running shed for 2 months so full advantage has been taken. The ashpan can be seen on the left which will have the damper doors completed. Tom (in orange) is sorting out the feedwater trays, James is needlegunning the cab roof and Barney and Keith are removing the corroded gutters and other fittings. Beyond that, Lee was cleaning the left hand tank before needlegunning will start. The new tubeplate has arrived and it is seen here on the radial drill where the remaining stud holes will be drilled. The new tubeplate is lifted into place. The tubeplate fitted. The cylinder covers have been refitted after having the relief valve holes machined as the original threads were in a very poor state. Paul and Alex continue to drill rivet holes in the flange of the new tubeplate. New oil pipes have started to be fitted to the horn guides and axle boxes. Jeff and Dave are fabricating the new front ring for the smokebox. The vacuum pump has been completely overhauled including having the body rebored, piston rings replaced, new metalic gland rings fitted and all valves ground in. The pump is seen here on the bench ready for refitting on the loco. The new front smokebox ring is now complete with the smokebox door hinges and other fixings fitted. Dick is seen here working on the final longitudinal stay hole out of 6 on the backhead. All others have been tapped to a larger size to restore the threads. Roger is seen here machining new window hinges for the cab. Marc machines the thread on one end of the longitudinal stay. The rest of the stay is projecting out the back of the lathe and is supported while it rotates slowly to screw cut the thread. Steve and Paul drill holes in the new smokebox for the rivets. After the top two longitudinal stays were fitted, Chris assembled the feedwater trays. A view inside the boiler showing the feedwater trays, the new longitudinal stays, new crown stays and the reinstated ejector exhaust pipe on the left. Chris and Paul work on the new smokebox after the front ring is fitted. The new smokebox is trial fitted in the saddle. The position of the fixing holes can then be determined along with the correct location of the chimney etc. One of the big end shells is clamped into the mould and the molten white metal is poured in to create the bearing material. Ralph drills holes in the bottom of the new smokebox for the fixings for the doubling plate. Steve measures the crank axle in preparation for machining the big end bearings. Chris machines the white metalled big end bearings. These will then be scraped to match the crank axle. The tanks are painted in green undercoat. Alex feeds another tube into the boiler. The boiler seen now with most of the small tubes fitted. The boiler is also getting a coat of heat resistant paint. The superheater flues are seen here being machined ready for fitting the flues. In this picture, the chamfer is being cut on the water side of the rear tubeplate. The tool is on the end of the long mandrel which runs the length of the boiler. Paul monitors the tool from the front of the boiler and relays signals from the firebox to the motor operater at the front. Water in the boiler! The boiler, now complete with smokebox, is warmed through after a successful hydraulic test. It is now ready for the boiler inspector to witness the official Hydraulic test. The pressure gauge reading 270 psi during a hydraulic test. Boiler inspector John Glaze inspects the firebox of 5637 with 200psi steam pressure showing on the gauge. The boiler successfully passed the hydraulic test in the morning. Paul adjusts the safety valves during the `out of frame` steam test which was witnessed by the boiler inspector. With all looking very good, we are now given the green light to start the final assembly process. Colin applies the first of the top coats to the new bunker. The first top coat applied to the bunker. The backhead is lagged and clad with some of the fittings also installed. The lubricator is fitted so that the oil pipes can be routed along the boiler before the remaining lagging is fitted. The number plates are painted in undercoat. Paul fits the new studs to the superheater header. The boiler is lagged before cladding. The new cladding is fitted. All but the rear barrel section fitted. Chris and James fit screws into the top cladding. A view along the top of the boiler showing the completed cladding. The rear section around the boiler will be removed for the boiler lift and then refitted before the tanks are put in place. The day of the boiler lift. The boiler is pulled out of the workshop... ...followed by the frames. The boiler was then lifted and positioned onto the ashpan. The boiler being lowered into the frames. The crane driver then took the opportunity to have a quick nap whilst the cladding was fitted to the final section of the boiler. The fully clad boiler and frames were then rolled back in order for the crane to pick up the tanks from another wagon. The right hand tank is fitted. The left hand tank and cab now fitted. The chimney is also fitted. Note the new firebars on the trolley ready for fitting. The new steam pipes and elements fitted into the smokebox.