LMS Patriot Project Updates

For any of you who are on Facebook or who buy the general railway magazine's (big article in Heritage railway magazine issue 222) might know, we have launched our Tenner for the tender appeal to help raise the £50,000 needed to complete the tender. The website is now updated with the appeal. Please visit http://lms-patriot.org.uk/civicrm/contribute/transact?reset=1&id=9 to donate. We would like to thank everyone who has donated to the project so far and urge anyone who wishes to donate but has yet to do so to please click on the link. Merry Christmas and a happy new year from the patriot team

 

The latest project up-date has been loaded to the projects web site this afternoon.

Engineering Up-date - December 2016
Submitted by Kevin West on 21 December, 2016 - 17:41
Locomotive Frame Assembly
As we work towards our target to be complete for 11th November 2018, the amount of work taking place at locations across the country is rising. As an example of this, the total value of orders raised by our Chief Engineer for the supply of parts and services for the construction of the locomotive, since the beginning of September is £102,288.00. That does not include staff costs at Llangollen or any work on the Boiler at LNWR Heritage at Crewe which is additional to this. We receive many favorable comments on the amount of simultaneous and speedy progress reported in these reports. The only way we can do this is with your continued financial support. While included in these orders are a few items that are of reasonable high value, the majority are for quite small numbers.

I can see little prospect for this level of orders to be reduced over the next 18 months if we are to meet our historically defined deadline. As I say in the talks and presentations I give about the project, we started as a bunch of idiots that wanted to build a steam engine, we are now building a War Memorial! As funding from any central or commercial organisations now appear to be less likely it is down to our supporters to step up again. We have a number of schemes running such as Tenner for the Tender and the Boiler Loans scheme. But the best way you can help is by signing up as a regular donor until the end of 2018. That is just 24 months, so 24 regular donations of whatever you can afford. £10 per month is a total of £240, not a vast amount. But if 10 people sign up it is £100 a month, if 100 do it’s £1,000 a month extra into our cashflow which allows us to pay for these parts and services.

To sign up as a regular donor, or sign up as a member, or make a one off donation please visit:-

http://www.lms-patriot.org.uk/sites/default/files/Patriot_Donations_Memb...

We need your support8 to be able to finish The Unknown Warrior for the 100th Anniversary of the Armistice on 11th November 2018.

Thank You.

Work continues on the construction of The Unknown Warrior at number of locations.



The Unknown Warrior outside the shed at Llangollen waiting the removal of the Crank Axle. 14th Dec 2016.. Photo – Kevin West

Following on from the last report work has continued on a number of fronts on the chassis at Llangollen.

The sample new Driving Wheel Spring has been fitted and approved. The remaining 5 are now in production for delivery in the early new year.



The new design Driving Wheel Spring trial fitted to the locomotive chassis. Photo – Kevin West

Installation of the replacement Stretcher 4 has almost been completed. We are just waiting for the supply of a last Fitted Bolts to enable this task to be completed. As previously found an order can be placed with a supplier and we assume all is progressing as expected. When the parts delivery does not happen as expected and enquiries are made we get told, sorry, I can’t get the material spec you want, or the machines are busy on other work. Very frustrating. These Fitted Bolts are now to hand along with new studs for the Cylinder Covers. This releases Llangollen to finish the fit of stretcher 4 and start on lining up and fitting the Slide Bars.

The Motion Girders are also ready for final fitting. Once again the special Bolts required have been ordered. The bolts required for the Front Buffer Beam have also been ordered. This has been done by a procedure that we have instigated following Dave Owen’s start as a volunteer on the locomotive. Rather than rely on using Llangollen Engineering stock of fastenings we are ordering in direct a stock of fastenings that we require. This will speed up assembly as we will not have to wait for parts when the stock is exhausted.

Permanently riveting the Platform sections in place has been started and is due to be completed before Christmas.

One job that we had not expected was the removal of the Crank Axle for some rectification work at the South Devon Railway. On a trial fitting of the Inside Motion Eccentric an issue was found with the keyway in the Axle.

The Axle was removed from the chassis on 15th December and transported to Buckfastleigh shortly after along with the wheel sets from LNER D49 Morayshire which is undergoing an overhaul at Llangollen. A repair method has been agreed and we expect a quick turn round and return to Llangollen for the Axle assembly.

A start has been made on fitting the mounting brackets for the Lubrication System Oil Boxes. Dave Owen has also signed up the services of the regular pipe fitter at Llangollen to install all the pipe runs on the locomotive.



Left Hand Trailing Axle Guide Oil Box Bracket trial fitted to the locomotive chassis. Photo – Kevin West

The Intermediate Reverser Shaft Bracket is being machined at Harco Engineering along with the associated Bearing Bronzes and Bearing Caps.



Intermediate Reverser Shaft Bracket undergoing machining at Harco Engineering. Photo – Kevin West

The parts for the cab Reverser have been put out for quotation. The first parts for the unit have been cast, the Pivot and the distinctive sculptured Reverser Wheel. These have been delivered for machining.



The Reverser Pivot casting. Photo – Kevin West



The pattern for the sculptured Reverser Wheel. Photo – Kevin West

The Inside Cylinder Exhaust Pipe has been machined and is ready for delivery to Llangollen.



The Inside Exhaust Pipe after machining. Photo – Kevin West

Brake System and Lubrication System
Work is continuing on the assembly and polishing of the Oil Boxes and acquiring the fittings required for the lubrication system. The first batch of pipework has been delivered to Llangollen and we anticipate that a start on fitting will be made in the new year.



2 of the Oil Boxes following polishing. Photo – Kevin West

The atomiser has been completed and delivered to Llangollen.



The finished Atomiser. Photo – Kevin West

Fittings acquired over the last couple of months include the non-return valves for the Driving Axleboxes.



A selection of the Lubrication fittings recently acquired. Photo – Kevin West



Another selection of fittings including for the Driving Axlebox Non Return Valves, bottom left. Photo – Kevin West

Manufacture of the locomotive Brake Gear components is complete and the parts are due to be delivered to Llangollen in the week before Christmas. This will allow David Hughes and the painting team to prepare the paint finish before a trial fit of the gear is made in the New Year.

The Brake Cross Shaft under the Cab was originally a forging and discussions are underway with our approvals body to see if we can use a casting or fabrication. A decision is a-waited on this before final design work is completed and quotations to supply can be sent out.

Following discussions with our approvals body we have decided to fit a brand new 10 ½” Brake Cylinder instead of refurbishing the 12” Cylinder from 8F No 48518. The 8F class were the only class of LMS locomotive fitted with the 12” cylinder. To use this on The Unknown Warrior would have involved either sleeving the cylinder down to 10 ½” and making a new Piston, Cover and Sleeve. Or making adjustments to the Brake Gear layout to reduce the brake force applied to the wheels. The news that a new cylinder was available at a very advantageous cost made the decision very easy.

We expect the new Cylinder to be delivered to Llangollen in the first few weeks of the New Year for trial fitting, the mounting assembly for the Cross Shaft is out for quotation and we expect to place the order in the next couple of weeks.

Refurbishment of the original 9” Tender Brake Cylinder from 8F 48518 continues at Harco Engineering.

Pistons, Valves and Motion
Work is progressing on the procurement and manufacture of the remaining Inside Valve Gear parts.

All parts for the Inside Connecting Rod Assembly are completed at CMS Cepcor. These will move to Llangollen for white metaling of the bearings and final boring at Llangollen to complete this assembly.

The two Outside Eccentric Rods have been machined by CMS Cepcor and are ready for delivery to Llangollen.



A selection of parts recently completed at CMS, including the 2 Outside Eccentric Rods and Brake Gear Pull Rods. Photo – Kevin West

An order has also been placed with Robert Stephenson & Sons of Manchester for the manufacture and supply of the Return Cranks.

Orders have been places for the Main and Intermediate Reverser Shaft castings. Quotations for machining these are out with our preferred suppliers.

The Inside Crosshead casting has been moved to CMS Cepcor for initial machining. The final machining will be undertaken at Tyseley in conjunction with fitting the Piston Rod.

The new Inside Combination Lever plus associated bushes and Oil Caps has been ordered for delivery in February.

The new Union Links we require, 1 Inside and 1 Outside, along with their associated Pins, Collars and fittings are out for quote.

Castings for the 3 Valve Crossheads have been ordered and final design work is underway on the Valve Crosshead Guides. We need to wait until the Outside Valve Guide Brackets have been fitted to the Motion Brackets. We will then be able to get exact measurement of the distance between the bracket mounting face and the centre of the Valve Rod to enable the valve guides to be finally machined.



The Valve Guide Brackets being prepared for painting at Llangollen. Photo – Kevin West

The 2 Outside Crossheads are due to move from Llangollen to Tyseley for refurbishment prior to fitting to the Piston Rods.

Work continues on the final design of the Piston Rods and Valve Rods.

Apart from the Inside Radius Rod, which is undergoing final detail design, once these parts are to hand all the Valve Gear Parts will be to hand.

At Llangollen, work is progressing on the manufacture and fitting of the new Bearings and Brasses to the Coupling Rods and Connecting Rods. Once complete we can expect an early trial fitting of the Coupling Rods to the chassis.



One of the Coupling Rod Bearings under manufacture at Llangollen Railway Works. Photo – Kevin West

Drain Cock Gear, Cylinder Relief Valves & Sanding Gear
Castings for all the Cranks and Levers required have been delivered and quotes are being obtained for these to be machined, along with all the Operating Rods, Pins, collars and associated parts.



The Cranks, Levers and Bracket castings for the Drain Cock Gear. Photo – Kevin West

On the Cylinder Relief Valves, the Valve castings have been obtained and sent to the machinist along with the Valve Cage castings. Quotations for the Valve Springs have being obtained and will be ordered shortly.

The 3 Drain Cocks we require, we already have 6 originals, have been ordered and should be available for fitting in the late spring 2017.

On the Sanding Gear the four front Sandboxes have now been mounted onto the locomotive chassis and are ready for the Sandbox Necks to be installed.



The Leading Sandboxes in position in the locomotive chassis. Photo – Kevin West

The Rear Sandboxes that are mounted on the Platforms alongside the Firebox, have been ordered from R D Moore Ltd along with the parts for the gear nozzle mounting brackets and plates.



CAD image of Rear Sandboxes in position on Chassis. Photo – Kevin West

The Sand Traps and Nozzles are about to start being refurbished by our Llangollen volunteers.



A Sand Trap and Nozzle prior to refurbishment. Photo – Kevin West

Fittings
The castings for the Injectors being manufactured for us by Tyseley Locomotive Works were spotted at CMS Cepcor for machining on a recent visit



Injector body casting alongside an original injector. Photo – Kevin West

Boiler
The Outer Firebox Doorplate has been drilled at LNWR Heritage, Crewe and the internal stiffening plate has been fitted. All the pads for the fittings on the Backplate has been made and are ready for riveting and welding in place.



The Outer Firebox Doorplate undergoing drilling at LNWR, Crewe. Photo – Kevin West



The Stiffening Plate mounted inside the Doorplate. Photo – Kevin West

Forming the Outer Throatplate at Tyseley Locomotive Works is progressing with the top section complete. Forming this top section is a two stage process using first a female former to form the flange that will fit to the barrel. Once this has been completed the plate is turned over and bolted to a second former that will creat the flange for the Wrapper.



The Barrel flange former with the wedge shaped used to support the bottom section placed on top. Photo – Kevin West



The plate bolted to the second stage former. Photo – Kevin West



Heating another section of plate before hammering can begin. Photo – Kevin West



Alistair Mealney works on another section of the flange. Photo – Kevin West



The finished top section of the Throatplate. The only section of plate that is in the same plane as the original sheet are the 2 sections in the corners where the 2 fixing holes have been welded. Photo – Kevin West

The lower section has been started with the flange that fits to the barrel formed. When the plate was moved onto the former that will be used to form the side flanges it became apparent that the former had distorted during casting, so some additional work was required on the former to allow the plate to sit correctly. This was disappointing, but work is now almost complete and the side flanges are due to be formed in the first week of January.

The Foundation Ring has been welded and tested and is now ready for fitting to the Boiler Assembly.

The Angle Ring which is the joint between the barrel and the Front Tubeplate has been delivered to LNWR Crewe.

The Inner Firebox Assembly is also progressing with work underway on preparations for riveting.



The Inner Firebox Assembly at LNWR, Crewe. Photo – Kevin West

The Dome and the Dome Cover castings have been delivered and quotations for machining are being obtained.



The Dome casting at Premier Patterns Works. Photo – Kevin West



The Dome Cover casting and Reverser Wheel casting at Premier Patterns Works. Photo – Kevin West

Final design for the mounting of the 8F regulator is underway. The regulator unit itself is presently on the Chief Engineer’s patio for measurement and will be returned to Crewe for refurbishment soon. The new J Pipe which connects the bottom of the Regulator to the Main Steam Pipe has been cast and will be going for machining soon.



CAD image of the 8F Regulator and J Pipe in the Boiler. Photo – Kevin West

Smokebox
The Main Steam Pipe Castings have been delivered, quotes for machining will be obtained in the next few weeks.



The casting for the Right Hand Main Steam Pipe at Premier Patterns. The square flange seen is the mounting for the Snifting Valve. Photo – Kevin West

The Superheater Header pattern is in manufacture with casting due in the first couple of weeks of 2017.

The final selection of base plates for the Smokebox have been made by R D Moore Ltd.



David Hughes painting some of the Smokebox Floor Plate at Llangollen Works. Photo – Kevin West

The Exhaust Seals have been cast and are away for machining.



The Exhaust Seals during machining at Harco Engineering. Photo – Kevin West

Investigations are continuing about the manufacture of the complicated Main Steam Pipes. We are discussing this with several other locomotive groups and railways who also require pipes for their locomotives.

A start has been made on the design of the Snifting Valves. These valves are fitted to the steam feed into each cylinder. When the regulator is open the steam pressure keeps the valves shut, but when the regulator is closed and the locomotive is coasting, the valves open and allow air to flow through the cylinders and stops a vacuum forming in the steam pipes and cylinders.



One of the Snifting Valves from Jubilee 45596 Bahamas at Tyseley Locomotive Works. Photo – Kevin West

The valves for the Outside Cylinders are mounted on the Main Steam Pipes above the Outside Cylinders and the one for the Inside Cylinder is mounted on the right side of the cylinder itself under the platform.



CAD image of the Snifting Valves (in green) in position on the right side of the locomotive. Photo – Kevin West

The original Chimney from 5539 E C Trench that the project acquired several years ago has been repaired and re-painted ready to be returned into the workshop as a donation collecting stand for the project.



CAD image of the Snifting Valves in position on the right side of the locomotive. Photo – Kevin West

Tender

Work on the refurbishment on the Tender Frames continues as work on the locomotive allows. The replacement Outer Frames are being prepared for attachment to the refurbished Inner Frame Assembly. This work will be undertaken as fall back work from the Locomotive Chassis is required over the coming months.

The order for the Tender Axlebox brasses has been placed. Once delivered they will be machined ready for wheeling the chassis.

Design work for the tender tank us in hand. We need to get the proposed changes approved by our approvals body before detailed drawings are prepared and quotations obtained for the profiling and delivery of the plate work.

Future Work Planning
As Christmas approached our Chief Engineer was coming under increasing pressure to move a number of locomotive parts that had found storage under the Dining Room table. The splasher and nameplate had been on display at the AGM and was waiting to be taken back to Llangollen. All parts were eventually moved to where required and domestic bliss restored!



The Chief Engineer’s Dining Room with a selection of parts from The Unknown Warrior in storage under the table! Photo – Kevin West

Future work on the locomotive at Llangollen is expected to include permanent fitting of the growing number of finished parts.

 

A message from our chairman now on the website.

Last year I wrote an end of year update and thought it would be a good idea if I repeated the exercise and demonstrated progress both from an engineering and fund raising perspective so far this year.



Most of you will be aware of engineering progress from The Warrior, our regular engineering updates on the website and our Facebook pages so I won’t go into detail on 2016’s achievements but it is worthwhile mentioning that we are now in a position where around 90% of the remaining components to complete the chassis are either complete, in manufacture or on order. The remaining items are relatively small but like everything to do with building a new steam locomotive expensive so there is a continuing need to keep funds coming in to pay for these items which will be required next year to allow Llangollen Railway Engineering to finish the job. On the boiler front, we wait only the delivery of the highly complex throatplate to complete the platework for the boiler. L&NWR Heritage at Crewe have nearly finished the door plate and once the throatplate appears will start assembly of the firebox, the most complex part of the boiler. Progress on the assembly of the tender chassis will progress as funds and time allow.

Fund raising is ahead of budget and ahead of last year. This year following our decision to issue hard copies of our really excellent magazine The Warrior, (thanks due here to Pete Sikes for his outstanding contribution) sponsorship of components in 2016 has been excellent. We have also made great strides in getting to our target of 500 regular donors, with 390 to date and rising all the time. What has also been notable has been the off the cuff donations from people who are not even members. Over the past two months I have written to three such individuals who have donated a total of £17,000 (£21,250 with Gift aid) a sure sign that we are attracting support from beyond our membership.

Next year will be our crunch year with the need to raise money as never before so if you have toyed with the idea of becoming a regular donor or making a one off donation 2017 would be the best time to help ensure that 'The Unknown Warrior' steams in late 2017/early 2018. I would like to thank all our volunteers for their hard work and commitment in 2016 year and to take the opportunity of wishing you all a very Merry Christmas and a happy 2017 and my thanks for your incredible commitment and support to the project over the past twelve months.

Kindest regards,

David Bradshaw, Chairman

 

The latest Engineering Update has been loaded to the projects website.

Engineering Update - January 2017
Submitted by Kevin West on 9 February, 2017 - 18:19
Locomotive Frame Assembly
Work continues on the construction of The Unknown Warrior at number of locations.

Unfortunately, I have to start this report with some very un-welcome news. Chris Collins, one of the 2 Llangollen Railway Engineering engineers that is working on The Unknown Warrior has suffered a heart attack and has subsequently spent some time in hospital. I am sure everyone will join us in wishing Chris a speedy recovery and look forward to seeing him back at Llangollen as soon as possible.



The Unknown Warrior inside the shed at Llangollen waiting for the return of the Crank Axle. Jan 2017.. Photo – Kevin West

Work has continued on a number of fronts at Llangollen in the last month.

Following dispatch of the Crank Axle to the South Devon Railway in late December, a meeting was held at Buckfastleigh in early January and the rectification work was agreed. The axle is due to return to Llangollen this week to be re-fitted in the frames.

The space released in the Frame Assy while the Crank Axle was removed has been used to advantage to allow work on fitting the Inside Rear Cylinder Cover and Slide Bars.



The Inside Slide Bars in process of being fitted. Photo – Kevin West

The Outside Cylinders have had the same work completed with Rear Cylinder Covers and Slide Bars now fitted.



The RH Outside Cylinder with Rear Cover in place and Slide Bars fitted. Photo – Kevin West

The Outside Valve Crosshead Brackets have been fitted to the front of the Motion Brackets. This has allowed the distances to be measured and confirmed from the mounting faces to the center’s of the Valve Rods to allow the Valve Crosshead Slides drawings to be finished and the parts ordered.



Outside Crosshead Bracket in position. Photo – Kevin West

Installation of the replacement Stretcher 4 and the Motion Girders has been completed following delivery of the required fitted bolts. The bolts ordered for the Front Buffer Beam are also to hand, although it is not expected to be fitted in the near future as access to the area around the inside cylinder is much easier with it removed.

Riveting of the Footplate Platforms is almost complete with just a few rivets near the front needing to be completed.

Brake System and Lubrication System
The Oil Boxes have all been machined and polished where they will be visible and are ready for mounting onto the locomotive. The majority of pipe fittings required are to hand and the actual fitting of the first pipe runs is expected to start in the next couple of weeks.

The locomotive Brake Gear components, Cross Beams and Pull Rods have been delivered to Llangollen and the painting volunteers are working on them. The new 10 1/2” Brake Cylinder is due to arrive at Llangollen in early March followed by the Cross Shaft and its associated support structure. All the pins and bushed required have been completed by Llangollen Engineering. This will allow the whole brake gear system to be assembled to the locomotive and checked. Only the Brake blocks themselves are required to finish the whole system.



The Locomotive Brake Gear laid out on the floor at Llangollen Works. The third Cross Beam should be in the Pull Rod clevis in the foreground. Photo – Kevin West



The detailed view of the Cross Beam, Bridle and Pull Rods. Photo – Kevin West



The Brake parts in undercoat. The 2 polished rods are the Outside Combination Levers formally fitted to Jubilee class Achilies.. Photo – Kevin West

Our approvals body have agreed that the Brake Cross Shaft under the Cab can be fabricated instead of the original forging. A forging for this part would be very expensive and time consuming, so getting approval for a fabrication is a saving in both time and cost. The drawings have been sent out for quotation and an order will be placed in the next couple of weeks.

Refurbishment of the original 9” Tender Brake Cylinder from 8F 48518 continues at Harco Engineering.

Pistons, Valves and Motion
Work is progressing on the procurement and manufacture of the remaining Inside Valve Gear parts.

The two Outside Eccentric Rods and the Inside Eccentric Rod have been delivered to Llangollen along with their associated bushes. A Start has been made on painting the Inside Rod.





The Outside Eccentric Rods following delivery to Llangollen. Photo – Kevin West



Rods Ends showing Oil Cap. Photo – Kevin West

Picture – Inside Rod



Last month I reported that all parts for the Inside Connecting Rod Assembly were completed at CMS Cepcor, ready to move to Llangollen. Unfortunately, I was misinformed and some final reaming of the taper pin holes was required. This should now have been completed and the parts readied for delivery to Llangollen. Once at Llangollen the bearings can be white metaled and final machined ready for fitting to the Crank Axle Pin.



Work continues on the manufacture of the remaining Motion parts we have on order, including Inside Combination Lever, Union Links, Crosshead, Main and Intermediate Reverser Shafts, Return Cranks, Valve Crossheads and the Cab Reverser Assembly.





Work continues on the final design of the Piston Rods and Valve Rods.



Apart from the Inside Radius Rod, which is undergoing final detail design, once these parts are to hand all the Valve Gear Parts will be to hand.



At Llangollen, work is progressing on the manufacture and fitting of the new Bearings and Brasses to the Coupling Rods and Connecting Rods. Once complete we can expect an early trial fitting of the Coupling Rods to the chassis.

Drain Cock Gear, Cylinder Relief Valves & Sanding Gear
All the parts of the Drain Cock Operating system including machining of cast Cranks and Levers and manufacture of Rods and Pins and fittings is progressing for delivery to Llangollen at the end of March. The Brackets and associated mountings for the Sanding Gear has been delivered to Llangollen and will be painted before being fitted to the Locomotive chassis.

The four front Sandboxes have now been permanently mounted onto the locomotive chassis the Sandbox Necks are being installed. The Sand Traps have been refurbished and the front four have been fitted to the Sandboxes.



The Leading Sandboxes in position in the locomotive chassis. Photo – Kevin West

The Rear Sandboxes are expected to be finished in the next couple of weeks.

Boiler
The final forming of the Outer Firebox Throatplate has been completed at Tyseley Locomotive Works and the parts delivered to LNWR Heritage at Crewe.



A view of a section of the Throatplate during heating before being hammered over the former. Each heating cycle takes 7 to 8 minutes to get the sheet hot enough for 30-40 seconds of forming. Tyseley Locomotives Works. Photo – Kevin West



The bottom section of the Throatplate following forming at Tyseley Locomotives Works. Photo – Kevin West



A side view of the Throatplate showing the 11 1/16” step below the Barrel flange. Tyseley Locomotives Works – Jan 2017. Photo – Kevin West



The two sections of the Throatplate at Tyseley Locomotives Works. In the foreground the Top section and behind the Bottom section standing upside down. Photo – Kevin West

Work is progressing at Crewe on the Inner Firebox Assembly and the Barrel assembly. Now all the Outer Firebox parts are on site is expected that assembly of the Outer Firebox will start in the next few weeks. A meeting to map out construction to completion is to be held in the coming days.

Tender

Work on the refurbishment on the Tender Frames continues as work on the locomotive allows.

Design work for the tender tank us in hand. We need to get the proposed changes approved by our approvals body before detailed drawings are prepared and quotations obtained for the profiling and delivery of the plate work.

Future Work Planning
Areas of existing design work include, Cylinder Cladding Sheets, Cab Footplate structure and tender tank.

 

Exellent updates thanks for keeping us informed.

 

Many Thanks for the extensive updates Gavin and Kevin, progress is looking really good!

Richard.

 

The latest Engineering up-Date have been posted on our website this afternoon.

Engineering Update - April 2017
Submitted by Kevin West on 28 April, 2017 - 14:41
Locomotive Frame Assembly
Work continues on the construction of The Unknown Warrior at number of locations.

This report starts with the good news that Chris Collins has returned to work at Llangollen following his medical issue earlier in the year.



A different view of the Unknown Warrior inside the shed at Llangollen. March 2017.. Photo – Kevin West

Work has continued on a number of fronts at Llangollen in the last month.

The Crank Axle has been reinstalled in the chassis following its return from the South Devon Railway where the Inside Eccentric was fitted.



The Crank Axle Assy with the Eccentric fitted outside the shed at Llangollen. March 2017.. Photo – Kevin West





Close up views of the Eccentric. March 2017.. Photo – Kevin West

Following the fitting of the Outside Valve Crosshead Brackets, measurements have been taken to enable the dimensions of the Valve Crosshead Slides to be established. The drawings have been finalized and the parts are now on order.



Front Outside Slidebar Fixings showing the bolts and castellated nuts. Photo – Kevin West

The Slide Bars are fitted permanently and the Oil Pot mounting holes have been drilled and tapped. Drawings have been prepared for the Oil Pots which are based on those fitted to 45596 Bahamas.



Oil Pot as mounted on 45596 Bahamas. Photo – Kevin West



Rear Outside Slidebar Bracket showing the fixing bolts and oil pot mounting. Photo – Kevin West

Other parts for the chassis recently delivered to Llangollen include the Trailing Sandboxes, which will be fitted to the Platforms alongside the Firebox. It is anticipated these will be fitted in the next couple of weeks.

All the Sanding Gear Brackets and Mounting Plates are at Llangollen being painted ahead of being fitted to the Chassis.

The Cylinders cladding sheets have been ordered and are due for delivery to Llangollen, where the mounting holes in the Cylinders will be drilled and tapped.

The three Drawbar forgings have been delivered to Llangollen. They will need machining at some time in the future before fitting.



The three Drawbar forgings. Photo – Kevin West

Brake System and Lubrication System
The major activity on the locomotive recently has been the fitting of the Brake Gear. The Brake Hangers have had grease lubrication nipples fitted by the machine shop prior to mounting into the Hanger Brackets.



The Brake Hangers prior to being installed. Photo – Kevin West

The gear was completed with the Cross Beams and Pull Rods for all the Driving Wheels.



One of the Brake Hangers installed. Photo – Kevin West



Left side Middle and Trailing Driving Wheels showing the Brake Hangers, Cross Beams, Bridle and Pull Rod. Photo – Kevin West



A close up view of the Middle Cross Beam, Bridle and Pull Rod. Photo – Kevin West



A close up view of the Brake Gear for the Middle and Rear Driving Wheels during assembly. Photo – Kevin West

The new 10 1/2” Brake Cylinder is still awaited at Llangollen following delays at the supplier. Once delivered it will be installed under the Drag Box below the Cab.

The Brake Cross Shaft Mounting Brackets were delivered to Llangollen on 26th April. This structure will be riveted together and painted before mounting in front of the Brake Cylinder under the Drag Box.



The Brake Cross Shaft Bracket structure following delivery to Llangollen and being loosely assembled. Photo – Kevin West



A view from above the Chassis showing the Leading Cross Beam ahead of the Crank Axle. Photo – Kevin West



The Brake Gear assembly shown from underneath the Cab. The Brake Cylinder and Cross Shaft Bracket will be mounted at the top of this picture under the Drag Box with the Trailing Pull Rod connected to the pin that can be seen this side of the Cross Beam. Photo – Kevin West

Following approval that the Brake Cross Shaft can be fabricated instead of the original forging, the drawings have been sent out for quotation and specification for the welding to be agreed. It is expected the order will be placed in the next couple of weeks.

All the Driving Wheel Springs are now being fitted, with those for the Crank Axle being the last to be installed.



The right hand trailing Spring in position. Photo – Kevin West

A start has been made on the manufacture and installation of the Lubrication pipework.



The first of the Lubrication Pipework being installed. These are for lubricating the Trailing Horn Guide Slides. Photo – Kevin West

The 8 feed mechanical Lubricator has been collected from the Great Central Railway at Loughborough where it has been overhauled. Along with the larger 16 feed unit these are now ready to fit to the Locomotive when required.

The 8 feed mechanical Lubricator. Photo – Kevin West

A start has been made on installing the fittings required on the Lubrication system. These include the Non Return Valves on the Cylinders and the pipe bulkhead fittings on the rear of the Inside Cylinder.



The non-return valves installed in the Valve chest of the right cylinder and the bulkhead fittings being installed on the rear face of the Inside Cylinder. Photo – Kevin West

Two of the pipe bulkhead fittings required the body diameter to be reduced slightly to fit into the cast holes in the rear bulkhead of the Inside Cylinder. This gave the Chief Engineer the excuse he needed to clear out the clutter from his workshop and machine the fittings as required over the Easter break.



A Bulkhead fitting in the lathe ready for machining. Photo – Kevin West



The Chief Engineer machining the Bulkhead fitting. Photo – Joanne Baddock

Refurbishment of the original 9” Tender Brake Cylinder from 8F 48518 continues at Harco Engineering.

Pistons, Valves and Motion
Work is progressing on the procurement and manufacture of the remaining Inside Valve Gear parts.

Llangollen Engineering continue on the manufacture of the Coupling Rod and Connecting Rod Brasses and Bearings. Once the Bearings are finished they will be pressed into the Rods ready for trial fitting to the Locomotive.





The Connecting Rods, Coupling Rods and Outside Eccentric Rods at Llangollen. Photo – Kevin West





Inside Eccentric Rod in the machine shop at Llangollen with fitting to the Front Eccentric Sheaf. Photos – Kevin West

Work is almost complete on the parts for the Inside Connecting Rod Assembly at CMS Cepcor, ready to move to Llangollen. The Big End Brasses will be white metaled and machined at Llangollen on arrival.



Inside Connecting Rod assembly in the machine shop at CMS. Photo – Kevin West

Also at CMS, the new Inside Combination Lever is almost finished, only requiring the oil reservoirs and oil ways need finishing.



Inside Combination Lever almost finished at CMS. Only the oil reservoirs and oil ways need machining. Photo – Kevin West

Work has started on machining the new Inside Crosshead. Once finished it will move to Tyseley Locomotive Works for finishing and fitting to the Piston Rod.



Inside Crosshead showing first stages of machining at CMS. Photo – Kevin West

Work continues on the manufacture of the remaining Motion parts we have on order, including Union Links, Main and Intermediate Reverser Shafts, Return Cranks, Valve Crossheads and the Cab Reverser

Assembly.



The castings for the main Reverser Shaft Balance Arms. Photo – Kevin West



Flame Cut Blanks for the Union Links and Inside Drop Link at CMS. 2 of the Union Links are for The Unknown Warrior, the third is for Jubilee 45596 Bahamas. Photo – Kevin West

Work continues on the final design of the Piston Rods and Valve Rods.



The Inside Radius Rod drawings have been completed and sent out for quotation. This is the final motion part required for the locomotive.



Manufacture of the many pins, nuts, bushes etc for the motion continues.



A selection of recently completed fittings for the motion work. Photo – Kevin West



Drain Cock Gear, Cylinder Relief Valves & Sanding Gear
The Brackets and associated mountings for the Sanding Gear are being painted prior to fitting to the Locomotive chassis.



The Sanding Gear Brackets and Plates in grey undercoat along with the Trailing Brake Pull Rods and a Driving Wheel Spring. Photo – Kevin West

The Trailing Sandboxes have been delivered to Llangollen and are being painted before mounting on the locomotive.



The Trailing Sandboxes. Photo – Kevin West



The Trailing Sandboxes being painted in primer at Llangollen. Photo – Kevin West

Boiler
Construction of the Boiler is now concentrated at LNWR Heritage, Crewe following delivery of the Throatplate components.



The two major parts of the Throatplate laid out at LNWR, Crewe. These parts are joined by rolled sections of plate which are welded into the gaps. Photo – Gavin Shell

The assembly of the copper Inner Firebox is also continuing in preparation for final riveting.



The Inner Firebox. Photo – Gavin Shell



The Dome and Dome Cover castings wait delivery to CMS for machining. Photo – Kevin West

The project has recently been donated the regulator handle from Jubilee class 45552 Silver Jubilee by member Tony Digby. At present we are unsure if it is possible to use this on The Unknown Warrior, but investigations will be undertaken shortly. It will be interesting to see if this can be used as it comes from then next loco number from The Unknown Warrior. Also the first batch of 10 Jubilees were originally ordered as Patriots. Tony also donated an LNWR Gauge Glass Lamp.



The Regulator Handle from Jubilee 5552 Silver Jubilee. Photo – Kevin West



The number 5552 stamped into the regulator handle. Photo – Kevin West



LNWR Gauge Glass Lamp. Photo – Kevin West

Tender

Work on the refurbishment on the Tender Frames has made considerable progress over the last couple of months as we have had two engineers working on it full time.

The new Main Frame Plates have been positioned and drilled ready for final riveting of the chassis assembly. The new Rear Beam plate is awaited delivery from the supplier. It will be drilled on arrival at Llangollen.



The Tender Chassis being set up. Photo – Kevin West



The Front Beam, drilled and in position ready for riveting. Photo – Kevin West



Closer view showing the Main Frame plate drilled and in position. Photo – Kevin West

The Tender Axlebox Bearing Brass castings have been delivered. A drawing is required for machining. The Axleboxes will need measuring first to enable the correct fitting dimensions to be established.



The Tender Axlebox Bearing castings. Photo – Kevin West

The changes we have proposed to make to the Tender body have been accepted by our approvals body. This means we can now start to finalise the design work and prepare the required detail drawings. This will require some liaison with prospective suppliers to ensure the design of the plates meets the manufacturing requirements.

Future Work Planning
Areas of existing design work include, Boiler Cladding Sheets, Cab Footplate structure and Tender Tank.



The Project sales stand at the recent Strictly Bulleid event at Swanage. Photo – Kevin West

All this work requires large levels of expenditure on part manufacture and fitting, so the work of our sales team in spreading the word at events up and down the country is vital to the continued progress. As well as manning the stand at events these are also very sociable events and new volunteers are welcome to join and help.



Gavin Shell and Kirsten Shell at Swanage. Photo – Kevin West



The Unknown Warrior, Llangollen 26th April 2017. Photo – Kevin West

 

This is impressive!

Is this the first new build Boiler made in England since the 60's?

 

Biggest almost certainly, but not the only new one - both Isle of Wight Terriers had entirely new boilers in the 1990s / 2000s; Firefly at Didcot; various other early locomotive replicas etc.

Tom

 

First new build Superheated boiler then???

 

You are going to struggle to machine the big end bearings on your ML7.

 

I should think so.

It will be interesting to see how the initial costs and long-term reliability / maintenance of the Patriot boiler stack up. There are quite a number of big locomotives that are now having really fundamentally large amounts of boiler work done, but notionally repairs; and I wonder at what point simply constructing new might start to look cost effective?

Tom

 

I think it takes a group like this to break ground and set the benchmark. (discounting Tornado becasue Germany/existing major workshop etc etc)

Others must have considered new build long before now, but have gone with the known quantity of mend and make do as opposed to the unknown quantity of starting fresh.

Once this one is done, I speculate we will see a step change and start seeing more new kettles.

 

Don't forget that 82045's boiler is currently being assembled too.

 

My money (if I had any!) would be on the batch construction of Swindon GWR No 1 boilers. Look at all the Halls, 28xxs and 2885s out there, plus the new Grange and the Saint!

Much respect to the Patriot team for all the amazing progress; this incredible project is really coming together now it seems. Just as well really as 2018 will be here very soon!

 

There is one advantage to mend and make do. That is paperwork. Existing boilers have grandfather rights. If it is a new boiler it has to comply with the Pressure Equipment Regulations 1999. That may sound easy but someone has to put their name to it. If you take an existing boiler design and plan to build new to it there are probably no supporting calculations and there needs to be. Most boiler design has evolved and is empirical and there are only two UK standards to work to; the obsolete BS931 on loco type boilers of riveted construction (which actually excludes railway locomotive boilers) and BS2790 for design and manufacture of shell boilers of welded construction. If you are designing a new boiler you can make it compliant but if you set out to prove that your existing boiler design meets either of these two standards, you will probably fail.