#10 Douglas

Heavy general overhaul of rebuilt J94

8th May 2008:       Douglas's cylinders are the last job before the boring machine is returned.   Click photo for movie version  (790KB, 8th May 2008)       Photo and movie (8th May 2008):  Tony Wood

22nd April 2008: Andy has been fitting palm stays* to the boiler of Douglas #10. To get inside the boiler (which is upside down) he'd wriggled up through the dome!   Nice shadows cast by the firebox tubeplate around the shell. Shot through a smokebox tubeplate hole. The palm stays secure the firebox tubeplate to the bottom of the boiler barrel (see 20th December 2007 report below)     Photo  (22nd April 2008):  Tony Wood   *Palm stays give added support to the firebox tubeplate Two diagrams reproduced with the permission of the author from his excellent reference book:  "The design, construction and working of Locomotive Boilers"  by Alan J. Haig C.Eng., M.I.Mech.E  (ISBN0-9545364-0-1)
20th December 2007: The riveting on the foundation ring and the firehole door ring on Douglas's boiler is now complete       Photos  (20th December 2007):  Tony Wood
	Andy, perfectionist as ever, was trimming the rivets with a curved pneumatic chisel. You can hear the din in the distance in the Movie of a Santa Special departing Ropley for Medstead today.  (2.2MB, 20th December 2007):  Tony Wood   Next jobs will be to complete the caulking of the seams with a straight pneumatic chisel, installation of the palm stays, which give added support to the firebox tubeplate near the throat plate, and the specified welding of parts of the firebox wrapper seams. Two diagrams reproduced with the permission of the author from his excellent reference book:  "The design, construction and working of Locomotive Boilers"  by Alan J. Haig C.Eng., M.I.Mech.E  (ISBN0-9545364-0-1)

 
Andy, Spud and Gavin were starting rivetting the foundation ring of Douglas's boiler   Movie  (6.8MB, 11th December 2007)

22nd November 2007: Left-hand cylinder rear cover of #10 Douglas had been poorly repaired in its previous life, so this will be ground out and stitched for a proper job     "Stitched"?     Photos (22nd November 2007):  Tony Wood

	25th October 2007:   Douglas on his wheels again and the trollies are now released for the next job   Wheeldrop
	Photos (25th October 2007):  Peter Smith

23rd October 2007:   Now that the bufferbeam is off, there's a usefully clear view of the slide-valve steam chest and ports of a J94 with front covers, valves and pistons removed.   In service, when the regulator is opened there is a 'clunk' as steam pressure throws the valves onto their vertical seatings   Photo (23rd October 2007):  Tony Wood
18th October 2007:     Back on his wheels - Brian and Bob peeping out   In the boiler shop, Andy was drilling the firebox foundation ring for rivetting. Note how the corner rivet hole is angled.
Photos (18th October 2007):  Tony Wood

17th October 2007:     The frames of #10 Douglas were raised by steam crane and his wheels were refitted
This view shows drivers axlebox, eccentrics and eccentric rods between the frames
	Photos (17th October 2007):  Peter Smith

11th October 2007:   Andy was drilling the firehole door ring of Douglas's boiler ready for rivetting.  In the main shed, springs were being assembled to Douglas's axleboxes. John Redgrave was busy at a lathe, trying to keep up with demand for spring hanger pins
Frank was machining the white metal of Douglas's big ends Photos (11th October 2007):  Tony Wood

9th October 2007:     This could have been the final shot of the movie showing the fitting of the firebox into Douglas's boiler but of course where there's a decent steam-tight fit, it always needs persuasion - which takes an hour or two !   Frank was machining the white metal of Douglas's big-end bearings on the vertical borer:    MOVIE  (850KB, 9th Oct 2007)    Photos and movies (all 9th October 2007):  Tony Wood

4th October 2007:   The brasses for Douglas's big-ends await machining on the vertical borer

Andy and Spud were installing Douglas's firebox   MOVIE (4th October 2007, 7.5MB)   Photos and movie (all 4th October 2007):  Tony Wood

2nd October 2007:     Steve has made a new cab floor for #10 Douglas             MOVIE: Douglas's big-end brasses being white-metalled  (5.5MB)         Photo and movie (2nd October 2007):  Tony Wood

29th August 2007:     In the shed, Douglas's driving axle has had eccentrics assembled     Photo (29th August 2007):  Tony Wood

1st August 2007:     Two views of work done the new firebox for Douglas's boiler   Foundation ring now fits inner and outer wrappers             Photos (1st August 2007): Andy Netherwood

24th July 2007:     View of the shed today from the mezzanine floor (l - r): #45379; Douglas on Warwell; cab of #45379; Toad (to Duncan's chagrin) only just arrived for titivating ready for our Thomas event; and in the forge area, Frank and team were white-metalling one of the eccentric straps for Douglas's valvegear
	Hugh was machining the white metal of another strap
	Bob was doing a few calculations for fitting Douglas's motion and axleboxes   Photos (24th July 2007): Tony Wood

17th July 2007:     In the boiler shop, Andy has been drilling pilot holes in Douglas's inner firebox, using the foundation ring as a drilling jig
The frames of Douglas are still on the Warwell, Hugh was machining probably the last eccentric strap and most of those he's done have been tinned ready for white-metalling.   Work has begun on axleboxes
Photos (17th July 2007): Tony Wood

	10th July 2007:    Springs have arrived. In the boiler shop Andy was working alone on the inner firebox and foundation ring, and making good progress with marking-out for drilling. "Having the drawings helps enormously" - he said
Hugh was machining the Stephenson valvegear eccentric straps       Photos (10th July 2007): Tony Wood

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3rd July 2007:       Gavin and Andy were fitting the foundation ring to Douglas's inner firebox   Photos and movie (3rd July 2007):  Tony Wood

11th June 2007:  
 
Hugh was machining the eccentrics for Douglas on the vertical borer:   Movie  (1.2MB, 11th June 2007): Tony Wood
 

30th May 2007:   The frames have been cleaned and were being painted today, valvegear eccentrics were being cleaned and the wheels have been painted

16th May 2007:     Inside Douglas's upside down boiler. Click photo to get it 'right way up'

Photo (16th May 2007): Tony Wood

26th April 2007:  In the Boiler Shop, Andy and Gavin were preparing to rivet the outer wrapper of Douglas's firebox and were checking their proposed setup on the cut-off scrap lower part of the firebox:    Movie  (2.8MB) (26th April 2007): Tony Wood

21st March 2007:   Gavin has made a new ashpan for Douglas, using the old one as a pattern     Photo (21st March 2007):  Tony Wood

13th March 2007:   Douglas's wheels are back from re-tyring Photo (13th March 2007):  Tony Wood

31st January 2007:   The 45-ton steam crane was called in today to turn Douglas's boiler onto its back for easier fitting of the inner firebox. Movie of this manoeuvre (31st January 2007, 10.5MB) Before the lift a broken spring was changed on the crane. Careful planning and organisation of the lift, precision movements of the 45-ton crane and the use of 'cushions' made from pallets resulted in a textbook operation     There's Thomas  (movie, 31st January 2007, 1.2MB)  warming up for test before going to meet his little friends at another railway

Photos and two movies (31st January 2007): Tony Wood

6th December 2006:   Andy was marking out Douglas's firebox patch for riveting   Photo (6th December 2006): Tony Wood

19th November 2006:         Thomas looks at Douglas on his wagon Photos (19th November 2006): Tony Wood

15th November 2006:     Busy day at Ropley with the 45-ton crane today: Frames of Douglas lifted from his wheels and put on a wagon.   Movie of this operation (3.8MB)
	Wheels loaded onto a lorry to go to Rileys' for new tyres
In the Boiler Department,  Douglas's boiler was turned onto its other side to give better access for patching the left-hand side of the firebox wrapper Movie of the lift  (3.5MB)
Photos and movies (15th November 2006):  Tony Wood

7th November 2006:     The patch on the lower right firebox wrapper of Douglas's boiler is in and welded. Corrosion patches on the boiler barrel have been remedied with weld too.   The rest of Douglas is in the wheeldrop shed and almost ready to be lifted from the wheels, which will go to Riley's for re-tyring. Today eccentric straps and big-ends were removed from the crank axle
	Photos (7th November 2006):  Tony Wood

17th October 2006:     Andy has discovered two minor cracks which will be ground out and built up with weld before the new throatplate and doorplate sections are welded on.   In this closeup, one of the cracks is revealed by magnetic particle inspection using a permanent magnet and a spray of fine iron filings in oil. White painting first makes the crack easier to see.   The file steadied the camera for the photo using existing light (1/30th sec) on 'macro' setting   Photos (17th October 2006):  Tony Wood

12th October 2006:     Up in the boiler shop, Andy had heated the doorplate of #10's boiler and had pulled it into position for welding, but first will have to demount the foundation ring and both patches for further weld-prep     Photo (12th October 2006):  Tony Wood

11th October 2006:     On the boiler for #10 Douglas (J94 modified to tender engine) the foundation ring, throat-plate and doorplate are clamped up ready for welding, though the doorplate has a bow of about 3/4" which may need some heat before it can be pulled straight.   The foundation ring was supplied by Robert Smith Steel, and Andy has described their profiling work as "excellent" Photos (11th October 2006):  Tony Wood

18th September 2006:   New firebox wrapper sections around the foundation ring of Douglas's (ex-Thomas) boiler have been made for throat-plate and backplate, and lower side-plate sections will be made.   The inner firebox tubeplate has been drilled for the tubes and pilot holes for crown stays. On the radial drill, Keith has been steadily progressing around the foundation ring     Photos (18th September 2006):  Tony Wood

30th August 2006:   Andy has been drilling the corners of Douglas's firebox foundation ring first; these angled holes have to be very accurate to allow room for the rivet heads on the inside. The corner holes yet to be drilled will not go right through, and will be threaded for screws because there's not enough room for heads on the inside. Photo (30th August 2006):  Tony Wood

24th August 2006:   Douglas's firebox wrapper patch Three photos (24th August 2006):  Tony Wood

21st August 2006: Douglas's boiler and the new lower throatplate and back head sections were formed at Ropley last week
Right: The formed plate being fitted to the new foundation ring     Douglas report and 3 photos (21st August 2006): Andy Netherwood

1st August 2006:   J94 boiler (ex-Thomas, destined for Douglas): Patches of corrosion on the barrel have been built up with weld and holes damaged during burning-out of stays treated similarly and re-tapped. The original firehole door ring is serviceable and Gavin was bringing it up like new. The new firebox has had pilot holes drilled for the crown stays, and those for the side stays are next.
	Photos (1st August 2006): Tony Wood

 

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30th November 2005:     The J94 boiler has been removed from Douglas #10 and Keith Loughlin was busy in the smokebox replacing plugs
	Now rebuilt J94 #10 Douglas awaits new tyres, and the boiler from Thomas when the firebox has been replaced. Photos (30th November 2005): Tony Wood

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16th November 2005:

Steam crane DS58 unloaded a coach bogie delivered this morning, and then made easy work of dismantling Douglas's cab ready for boiler removal. Brake rigging has been removed underneath for Douglas's wheels to be removed     Photos (16th November 2005): Tony Wood

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9th November 2005:     In the yard, Jim and his team were preparing Douglas for boiler removal (to transplant into Thomas in time for the Easter event)   The chimney was removed for work to remedy the poor draughting of this boiler   (Photo and Movie, 3.9MB, 9th November 2005): Tony Wood)