31/1/17 - Pansy

This evening's work was to finish the barrel clamp jig and cut the hole for the dome.

A rather elaborate style holding jig for a 5" barrel was made to be able to get the hole square to the barrel and on centre with a rigid setup. A test piece of copper was used to try out a 40mm holesaw and see what sort of finish was possible. The diameter even with eccentricity on the holesaw was perfect for the dome flange.

The jig was clamped to the mill table and centre punch mark was lined up with the spindle. I ran out of Z travel on the table to fit the holesaw so it had to be done in two operations, drill the pilot hole and then fit the holesaw in. (The 4 inch head raising piece for a Bridgeport mill would be an advantage!)

The mill was set to low speed and the quill was driven off the handwheel with the quill lock half on to prevent any grabbing. Once the holesaw had cut a groove it didn't complain or chatter and rather uneventfully finished out a nice hole.

Clamp jig was dismantled to try the dome, which was just a little tight. A quick file to remove a burr made all the difference and it fitted perfectly square without any forcing one way or another, aligning off the machined hole as expected. The scriber traced the barrel inner profile  onto the dome to file that to shape.

This is a key thing to be aware of as the protrusion of the dome into the barrel sets the maximum height of water in the boiler. Once the steam entry into bottom of the dome is blocked by the water, a column of water goes right up the dome and into the main steam pipe.

A couple of boiler shapes I've seen,  notably the NSW 12/13 class could pick up water quite readily at half a glass if using the conventional steam collecting setup of dome and regulator. The stepped height between top of outer firebox and the barrel and the positioning of top gauge glass fitting on top of the firebox means the water level can very well be half a glass and begin priming! A long gauge glass in that case can be deceptive as to how much water can be carried before priming.

Some locos with tapered barrels have a cheat of a parallel barrel under the cladding, this too can be one to watch for. Naturally the steam should be coming from the highest point in the boiler, so a dry pipe should be run to the top of the firebox to eliminate this.

I have well digressed, it must be late!

Happy steaming!

Nigel

31/1/17 - Britannia

Today's work involved finishing the dumping centre grate. It has a stand and a sloping ledge in the ashpan that it sits on (so the ash falls off).

After the brazing work on the ashpan, the ashpan and boiler were assembled to the loco frame and trailing truck installed. The grates inserted up through the trailing truck frames and into the boiler, sitting on the ledge either side of centre. The centre grate portion was then installed into position using the new designed stand.

All worked very well and I thought it was a very easy matter to be able to install and remove grates. The stand on the centre grate required a loop on the bottom of the stand to hook it with a fire poker and pull it off the ledge. So the bits were removed and a bit of stainless rod was welded to the stand. Again another trial fit proved successful.

The ashpan seems to be structurally finished at least for now. A couple of brackets are required on the outside to hold various valves but these can be done with thru holes and nuts on the inside. Of course there is the damper lever and rod which will dummy up to the running board, none of that works or is hinged, it won't be highly obvious in the scheme of things.

The ashpan needs a sand blast and a good couple of coats of hi temp paint. It's steel and in the rust zone for sure, I didn't think I could do the amount of fab neatly in stainless!

Below are some pics of how it ended up looking. The views on the loco are looking up from below the trailing truck.

I definitely think the centre portion held up by a stand is an alternative for future designs.

Happy steaming!

Nigel

Update

Boy, the heat is back with a vengeance! Certainly enjoying the insulation in the shed! Australia Day holidays are a nice way to wrap up January.

Mentioning, again, the laser cutting/water jet cutting service for Model Engineers is back in action for the year, with a couple of jobs underway as we speak. A 2-3 business day quote and a 1-2 week manufacture time from placement of order. Postage is available to  anywhere in Australia so even for those out of state we will be happy to quote and send direct.  You can read more about it on our website under "Laser Cutting".

I'm trying to source some 5" x 3mm wall thickness copper tube for stock and some boilers. This is one of the most common diameter boiler barrels in 5" gauge. I have rolled some before which is still an option but makes for a bit of work. We need to believe God for a miracle! I hope to hear back from a supplier soon on that.

Through the Model Engineering work we've been able to do since we started, we have been able to support Mission work and child sponsorship. We have 2 sponsor kids in Burma who don't speak English, a brother and a sister. The boy loves soccer and wants to be a Church Pastor when he grows up. In years gone by I've sponsored a boy in Nicaragua through Compassion. He was able to complete the program at 18 and move onto being a man. It was an amazing feeling to look back and see how long I'd supported him and he was now exiting the program, with a good education and health care. We had kept in touch the whole time with letter writing. There's something exciting about doing something beyond ourselves and taking care of others.

How are your live steam projects going? Maybe drop us an email or comment to say "hi"!

Back to the workshop!

Happy steaming

Nigel

24/1/17 - Britannia

Before I get into the story, I think the blog post name including the date and the loco will be a good way to organise these blogs. It will be easier to search and view by loco project...there are a few currently on the go!!  Somehow less dull than "loco update, loco update, loco update"!

OK, back to the Britannia...

The grates needed a trim off the length and few notches out of the corners to fit the firebox but after that was done, they sat in the correct place. They sit on the ashpan and a ledge at the front, with the ledge trimmed in the centre to allow the centre portion to drop down.  The firebox tapers in all directions and it was a trick to get the bits in place and also removable through the ashpan hopper. I hope it's a success, it will be only able to be dumped in the steaming bay where access is possible between the tracks.

Those that have been following this build have seen the original Winson design and also the Norman Spink design have grates that are made from bars and spacers, with a dropping portion in the centre forward half.

The problem I forsaw with this scenario is the grate is trapped in and can't be removed without pulling the loco apart, a real pest if it bent or burnt out by clinker and strange coals we are getting these days! The whole thing was under designed from a maintenance perspective.

The grates now in position are made from stainless steel water cut plate, tapered bars and all. (If you want one, get in touch with us as our supplier has all the right gear). The grate is in 3 portions, the centre section is entirely removable and so makes room to get the other side portions out through the middle.

The next thing to sort out is how to keep the middle portion in place. I'd thought of the conventional cross pin underneath the grate but I don't think it's the easiest to line up with the holes in the ashpan as its a long way across. Also prone to bending over time. Plus it's another challenge to hold the grate up while trying to put the pin through! I must have piano fingers nice and slender, some other blokes have kranskys!

So the play time yesterday involved making a swinging stand under the centre grate that will sit on a ledge in the ashpan. Also helps removal as the stand can be used to pull the grate out and put it in. 

One of the challenges I face in model engineering is visualising a solution that will work in all cases as a standard fix, less time designing an easy-to-use solution will be a big plus. I think the stand under the centre grate may be a goer, I'd like a bit of feedback as to how it performs in service!

Below are some pics looking through the firehole...

Laser & water jet cutting

If you've designed your loco bits on CAD and are now looking for somewhere to get them laser cut, why not try our service?  Many customers have, and are now realising the benefits of using us to deal direct with the laser cutter.  Our supplier is also a fine Model Engineer, and knows how to set up the machinery to get a great result.

But what's new this time?  Firstly, we now have a CAD template on our website that you can download to start organising your order.  This streamlines the process for everybody, and helps you work out what you want.

Secondly, on our website we have a contact form and file uploader, so you can send us the CAD file and your details for a quote.

Thirdly, we will endeavour to obtain a quote for you within 2-3 business days, which will include postage direct to you.


Finally, we want you to experience an enjoyable and smooth process. We'd like to hear your feedback once you receive your order.

Happy steaming!

TrainAge

You may have noticed a link to TrainAge on our website! 

Somewhere back in 2015 a couple of friends approached us for some full size NSW loco numbers in the correct font to mount on their wall. Brass numbers weren't an option so the request was "Can you cut them in MDF and we paint them up ourselves in brass or chrome paint?

The shenanigans by one customer in the following weeks where 3801 chrome painted numbers were stuck on the side of an industrial 0-4-0 saddle tank loco were hilarious!

Since then different kits and defunct railway company logos have been developed, having sent them all over Australia. The 3D embossed effect of raised letters and shapes on the logo kits make a stunning deviation from a standard 2D sticker. The parts get painted and glued on a backboard of your choice, some have opted for a different shape or size, it's up to you how you want to mount them!

The railway station nameboard letters which are cut in Marine Hardwood Ply are also popular, some full-size and half-size signs have been built and others repaired using them. Live steam train clubs have used the letters for their stations and platforms. The heavy duty wrought iron bracket we sell has been measured off originals, hot scroll bent and welded, and drilled ready to go. The station nameboards and "tablet" signs such as Tickets are designed from standard mouldings and timber available from a hardware store, a drawing gets supplied with each order to guide you as you build.

Many of our new and young customers (not live steam guys) have enjoyed building the logo kits and mounting them on a back board or office wall or train set. They've sent us the photos of what they were able to do and in all cases it looks incredible, and it's always great to have the feedback. Thanks to the many who have made requests of what they want developed also

Not everyone is able to undertake a live steam loco or build a train set due to space restrictions, but you can have a fun few evenings putting together one of the kits or building yourself a station name board. For instance, you can use the nameboard letters to build a sign "Such-and-such Workshops" for your garage if you like to tinker, and enjoy the subtleties of the correct NSW or Victorian Railways fonts which have all been traced. Don't be afraid to be creative, the kits are to help you think outside the box!

If you are ordering letters or numbers, order the quantity of letters you require (add to cart) and put a note in the PayPal purchase telling us which ones you require. We now get instantly notified through PayPal of all orders, and your order will be despatched within 1-2 business days. 

Happy steaming!

www.npwoolley.com

Ashpan

Thankfully the weather has cooled off a bit which makes workshop work much more pleasant!

The Britannia's boiler was set up in the mill to drill and tap some holes in the foundation ring to hold the ashpan onto the bottom of the boiler.  The bolt holes in the ashpan were thought out as to where to fit them clearing some cross drilled holes through the foundation ring and being out of view as much as possible.

Some brackets were made and bolted to the milling machine table which I could attach ratchet straps to. A very good way of holding strange shapes!

Welcome 2017!

Finally the Christmas break is over for us, and back into work this week.  I was hoping to make a start middle of last week, but only managed a shed tidy and a play with the capstan lathe, before some yard work and other things took priority!  This is the first year I have not worked through the period and time off was very refreshing.

We are expecting hot weather again this week, and I am certainly looking forward to lining the roof with insulation a bit later on when it cools off, it's a take-the-tin-off job.  Four Aussie summers in a hot tin shed is enough...the radiant heat from the underside of the tin certainly heats up the benches and the machines!  Some days reach 40-45 degrees and with the fans on feels like a fan-forced oven! 

On the work front, we are kicking off with prepping an order for laser cutting, (if you have stuff you need cut as well, send us an email).  The Britannia work is ongoing, the small jobs relating to the boiler/cladding/and what's under the boiler between frames will get looked at.  The Holmside boiler can go off for some welding of boiler guides and smokebox engaging ring.  The Pansy boiler will progress closer to completion, and hopefully the Princess Marina boiler can be finished, as only the regulator and longitudinal stays require manufacture.

Most importantly for this year I want to step up support for Christian mission work (as we have done over the last 4 years) and looking for opportunities to network with other organisations doing the same.  Our lives have been so changed, and continue to change the more we follow our Saviour Jesus Christ who gave his life for us all on the Cross.

A dream come true (I have many) would be to production-run some wagons and each wagon have a story of sponsoring a child or similar...putting some real life-changing purpose into our hobby of Model Engineering.  How can we practically do that?  I guess we will have to wait and see!

Anyhow, don't forget to SUBSCRIBE to our blog for updates, keep checking the website for new sections, and send us an email if you have comments, suggestions, or want to discuss your job.

Happy steaming!

Nigel