As we are restoring 6029 outdoors we always make a note as to what we can expect with the weather for the upcoming workday. Showers with the possibility of rain and at 9am things were quite wet. Lucky for us the showers had cleared by lunch time and ironically we were feeling the effects of the sun by day’s end. As most of the loco ops guys were in Sydney with our operating locomotive 3016, the BBQ was held down on the 6029 work site. The 4468 diesel guys came over for lunch and as usual we solved all of the world’s problems before we went back to work.
The first bogie is now almost complete with only a few minor tasks left to do. These being the fitting of the pedestal keep plates and the manufacture of a new centre pivot bowl. The lateral control springs had to be fitted before lowering the frame into position. They were assembled with the aid of the ten ton hydraulic portable power pack. It took a few goes and we were all happy when the last pin was fitted. The reassembly went very smoothly, however the bolts holding the inner manganese liners had to be modified as they were rubbing against the suspension equalising beams. The bogie work site is starting to look like a traditional bogie repair shop and visitors can now compare a completed bogie with the striped down version.
Ian is continuing to fit the boiler cladding sheets and as a result of his efforts the drivers side is now complete. He is now concentrating on the fireman side. Now that drivers side cladding is fitted the injector feed pipes and starting valve were trial fitted and as expected some adjustments are required. Paul removed the old insulating rope to facilitate the annealing of these pipes. One advantage of copper feed pipe is that they can be adjusted for alignment after annealing. Unfortunately steam engineering of the 1950’s didn’t allow for true replication with manufacturing. As a result of this each boiler is slightly different dimensionally and most pipes have to be adjusted for fit. Ian has also experienced this issue with the cladding sheet metal and several trail fits and adjustments are required before final fitting.
Our next workday day is Sunday 21 March 2010.
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Mar 8, 2010
Mar 4, 2010
Progress happens when you are not looking
Progress is being made all over the place. Photos below show the progress being made on the super-heater elements in Melbourne while in Sydney, some more exposed metal has been painted and the long awaited reassembly has started on the cab at Eveleigh.
Included is a picture of the Garratt in 1975, when it was last painted. A scene not too far away, as long as donations keep coming in.
Included is a picture of the Garratt in 1975, when it was last painted. A scene not too far away, as long as donations keep coming in.
Feb 23, 2010
Sunday 21 February 2010
Again work is continuing on the bogies with yet more grime removal. Stuart and Paul experienced the joys of broken stud removal. Typically these studs are rusted in solid and the only way to remove them is by drilling them out and re threading by means by of a tap. No not something that is attached to a sink, rather the tool that cuts the thread. The centre has to be accurately marked and centre popped. A small pilot drill is applied and then the tapping size drill is last to go through. A small picking chisel extracts the remanding thread and the tap is screwed through by means of the tap wrench. Sounds easy but its not, as it is very easy to drill off centre and a slight change of angle can be disastrous. Fortunately Stuart served his apprentiship with the Victorian Railways at it Newport workshops. Stuart advised that it had been some time since he had done this type of work however with only one broken drill by days end this was judged as a good result. Stuart shared his skills with Paul and as a result both are now qualified as stud extractors or words to that effect! One can picture them as bouncers at a night club extracting studs. After they were finished with the studs the bogie was given its fist coat of black paint.
After cooking the BBQ Barry set to the leading head stock by use of the electric grinder and wire brush. As usual most of the old paint flakes ended up on Barry but the headstock now looks great.
Alan cut out the rusted centre bowl from the from the leading inner bogie. This should delight our bogie guys Kyle and John as both had the day off due to other commitments. Safe to come back guys, jobs done! In truth both have done a magnificent job so far, and a day off now and then is well deserved.
A big thankyou to all who organised the fund raiser trip to Kandos on Saturday the 20th of February. Thanks also to all who supported the project by purchasing tickets. Last but not least a thankyou to 3801 LTD for making their carriage available, it was a great day out.
The next workday will be Saturday the 6th of March.
Alan
After cooking the BBQ Barry set to the leading head stock by use of the electric grinder and wire brush. As usual most of the old paint flakes ended up on Barry but the headstock now looks great.
Alan cut out the rusted centre bowl from the from the leading inner bogie. This should delight our bogie guys Kyle and John as both had the day off due to other commitments. Safe to come back guys, jobs done! In truth both have done a magnificent job so far, and a day off now and then is well deserved.
A big thankyou to all who organised the fund raiser trip to Kandos on Saturday the 20th of February. Thanks also to all who supported the project by purchasing tickets. Last but not least a thankyou to 3801 LTD for making their carriage available, it was a great day out.
The next workday will be Saturday the 6th of March.
Alan
Feb 7, 2010
Saturday 6th of February 2010.
The rebuild of the bogies continues, all be it slowly. Kyle and John completed the assembly of the first equalising beams and main springs assemblies. The bogie frame is almost ready to be lifted on the wheels. The centre pivot liner must be replaced and our efforts to date have only realised colourful language and frustration. Kyle and John have assured us that they will have the liner extracted at the next workday. Vince cleaned up the four horn keep plates as they will be needed when the bogie frame is lifted onto the wheels.
Malcolm cleaned down and crack tested the eight manganese liners for the second bogie. Only sixteen to go hey Malcom! These liners were completely seized against the axle boxes.
Peter Anderson, Peter Reynell and the Alan stripped down the Nathan lubrication system around the leading unit cylinders. This allowed access to the engine bed and cylinder castings. The build up of baked on cylinder oil and grime in this area is significant. This grime is up to 25 mm thick and the use of the steam cleaner made no progress with its removal. Most of the day was spent chiselling baked on cylinder oil by hand. As the lubrication components were removed they were carefully tagged and stored for eventual overhaul. Lots of home work for the project manager.
Our next workday is Sunday 21st of February.
Malcolm cleaned down and crack tested the eight manganese liners for the second bogie. Only sixteen to go hey Malcom! These liners were completely seized against the axle boxes.
Peter Anderson, Peter Reynell and the Alan stripped down the Nathan lubrication system around the leading unit cylinders. This allowed access to the engine bed and cylinder castings. The build up of baked on cylinder oil and grime in this area is significant. This grime is up to 25 mm thick and the use of the steam cleaner made no progress with its removal. Most of the day was spent chiselling baked on cylinder oil by hand. As the lubrication components were removed they were carefully tagged and stored for eventual overhaul. Lots of home work for the project manager.
Our next workday is Sunday 21st of February.
Jan 20, 2010
16-17 January 2010, The hard slog!
16-17 January 2010, The hard slog!
The success of our first super weekend for 2010 cannot be understated. However having said that, the work on the four bogies is not glamorous or exciting, rather its dirty and very exhausting work. The many years of outdoor storage coupled with the loads of grime is gradually being overcome. To this end our dedicated team completed the strip down of the second bogie. The usual crack testing and extensive use of the electric wire brushes facilitated the application of grey primer paint. The assessment of the stripped down bogie is as follows.
1. Bogie frame casting cleaned, crack tested and prime coated. All mounting studs to be replaced with new.
2. 8 off manganese horn liners, replace 2 and repair 4.
3. Replace all bushes and some suspension pins.
4. Replace 2 off bogie bearing springs, very expensive fortunately we have several spares in stock.
The main roller bearings will require assessment, however 30 years of grime will have to be removed first.
The third bogie strip down commenced but the ability to access the bolts was hampered by inches of baked on grime and cylinder oil. This bogie supports the leading unit cylinders and it seems that the NSWGR railway maintenance crews didn’t have pay for the bill for cylinder oil. Further visual investigation around the leading cylinders confirmed that all the oil lube lines are either loose or in very poor condition. These lube lines are high pressure hydraulic type and they are not cheap to replace.
Work continued on the boiler cladding around the fire box area. The re-use of the sheet meal that came off the old boiler is causing Ian a few headaches. However the end result is a site to behold.
The MHG service van now has 415v and 240V power and lights. We are now on the lookout for a fridge and hot water unit or at very least a kettle. A big thankyou to Pat the electrician for his work on this van.
By the end of the two days all of the team were happy to go home and like me probably spent a significant amount of time in the shower scrubbing off dirt and grease.
APPEAL FOR HELP TO FINISH THE BOGIES x4
As the bogies are going together we are putting together an accurate cost against this critical work. When we finish the bogies the locomotive will start to go back together. However without the funds we will have to defer the reassembly until we have the finance.
We need $ 10,100
• $3,200 : Hydraulic pressure hoses. Theses hoses deliver the oil to the horn guides from the Nathan mechanical lubricators.
• $2,000: To replace broken manganese horn liners.
• $2,500: To replaced the bogie pivot bowl liners.
• $1,000: For replacement of studs, bolts washers.
• $1,400: For the replacement of worn bushes and pins.
Sponsor a specific item.
Naturally any donation helps, however we are also asking to donate against a specific item. For example if a donation is offered against an item from the above list, a certificate will be issued. This certificate will be an official 6029 donation certificate listing the item and the downers name. Because all of the items listed are over $1,000, two free tickets will be allocated for the first official run of 6029.
Remember we are at the turn around point, when the bogies are finished we start on the home straight!
Alan Gardner
The success of our first super weekend for 2010 cannot be understated. However having said that, the work on the four bogies is not glamorous or exciting, rather its dirty and very exhausting work. The many years of outdoor storage coupled with the loads of grime is gradually being overcome. To this end our dedicated team completed the strip down of the second bogie. The usual crack testing and extensive use of the electric wire brushes facilitated the application of grey primer paint. The assessment of the stripped down bogie is as follows.
1. Bogie frame casting cleaned, crack tested and prime coated. All mounting studs to be replaced with new.
2. 8 off manganese horn liners, replace 2 and repair 4.
3. Replace all bushes and some suspension pins.
4. Replace 2 off bogie bearing springs, very expensive fortunately we have several spares in stock.
The main roller bearings will require assessment, however 30 years of grime will have to be removed first.
The third bogie strip down commenced but the ability to access the bolts was hampered by inches of baked on grime and cylinder oil. This bogie supports the leading unit cylinders and it seems that the NSWGR railway maintenance crews didn’t have pay for the bill for cylinder oil. Further visual investigation around the leading cylinders confirmed that all the oil lube lines are either loose or in very poor condition. These lube lines are high pressure hydraulic type and they are not cheap to replace.
Work continued on the boiler cladding around the fire box area. The re-use of the sheet meal that came off the old boiler is causing Ian a few headaches. However the end result is a site to behold.
The MHG service van now has 415v and 240V power and lights. We are now on the lookout for a fridge and hot water unit or at very least a kettle. A big thankyou to Pat the electrician for his work on this van.
By the end of the two days all of the team were happy to go home and like me probably spent a significant amount of time in the shower scrubbing off dirt and grease.
APPEAL FOR HELP TO FINISH THE BOGIES x4
As the bogies are going together we are putting together an accurate cost against this critical work. When we finish the bogies the locomotive will start to go back together. However without the funds we will have to defer the reassembly until we have the finance.
We need $ 10,100
• $3,200 : Hydraulic pressure hoses. Theses hoses deliver the oil to the horn guides from the Nathan mechanical lubricators.
• $2,000: To replace broken manganese horn liners.
• $2,500: To replaced the bogie pivot bowl liners.
• $1,000: For replacement of studs, bolts washers.
• $1,400: For the replacement of worn bushes and pins.
Sponsor a specific item.
Naturally any donation helps, however we are also asking to donate against a specific item. For example if a donation is offered against an item from the above list, a certificate will be issued. This certificate will be an official 6029 donation certificate listing the item and the downers name. Because all of the items listed are over $1,000, two free tickets will be allocated for the first official run of 6029.
Remember we are at the turn around point, when the bogies are finished we start on the home straight!
Alan Gardner
Jan 3, 2010
Saturday, 2nd of January 2010
As previously reported the four bogies are the main focus of work until they are completed.
•Bogie number one was moved in preparation of its lift back onto its wheels. The wheels are now in place on the track adjacent to the bogie frame. The centre pivot casting was fitted onto the bogie frame to facilitate the fitting of the lateral control springs. Once the lateral control springs are fitted the bogie frame will be lifted onto the wheels, equalising beams and main springs.
•Bogie number two was stripped down to almost the last nut and bolt. However one wheel set was seized solid in the horn guides.The use of crow bars and our hydraulic porta-power facilitated its removal. This bogie was situated directly below the cab and a consequence of this every passage and hole was literally filled with coal dust and cylinder oil. The crew anticipates many enjoyable hours removing all the gunk and grime....NOT!
•Bogie number three was rolled out clear of the leading engine unit. As anticipated, it's condition is better than the first two, as it is further away from coal dust, heat and cylinder oil. No work will take place on the bogie until the first two are completed. Its overhaul will be faster as there is no brake gear on the outer bogies.
•Bogie number four, being the last, is still in place at the outer end of the hind unit. The King pin and guard iron’s will have to be removed before it can be rolled clear of the engine units. A line up of all staff will take place at the next work day to determine who is the smallest and skinniest member of our team. This lucky person will have the privilege of removing the last of the four king pins. Did we mention that this is the dirtiest part of the loco!
Thanks to Kyle, Stuart, Barry, Paul, Mike and Peter. These guys, and John (wasn’t in today), are fast becoming 60 class bogie experts.
Back over at the boiler, Ian continues to beaver away with the fire box crinoline support bands. He's also prepping the sheet metal for its final fit once the crinoline bands are completed. Mike has delivered the safety valves x 3. He has also finishing the rework of the front end regulator cams and valves at his Sydney workshop.
The next workday is Sunday the 17th of January, all welcome.
Alan Gardner.
•Bogie number one was moved in preparation of its lift back onto its wheels. The wheels are now in place on the track adjacent to the bogie frame. The centre pivot casting was fitted onto the bogie frame to facilitate the fitting of the lateral control springs. Once the lateral control springs are fitted the bogie frame will be lifted onto the wheels, equalising beams and main springs.
•Bogie number two was stripped down to almost the last nut and bolt. However one wheel set was seized solid in the horn guides.The use of crow bars and our hydraulic porta-power facilitated its removal. This bogie was situated directly below the cab and a consequence of this every passage and hole was literally filled with coal dust and cylinder oil. The crew anticipates many enjoyable hours removing all the gunk and grime....NOT!
•Bogie number three was rolled out clear of the leading engine unit. As anticipated, it's condition is better than the first two, as it is further away from coal dust, heat and cylinder oil. No work will take place on the bogie until the first two are completed. Its overhaul will be faster as there is no brake gear on the outer bogies.
•Bogie number four, being the last, is still in place at the outer end of the hind unit. The King pin and guard iron’s will have to be removed before it can be rolled clear of the engine units. A line up of all staff will take place at the next work day to determine who is the smallest and skinniest member of our team. This lucky person will have the privilege of removing the last of the four king pins. Did we mention that this is the dirtiest part of the loco!
Thanks to Kyle, Stuart, Barry, Paul, Mike and Peter. These guys, and John (wasn’t in today), are fast becoming 60 class bogie experts.
Back over at the boiler, Ian continues to beaver away with the fire box crinoline support bands. He's also prepping the sheet metal for its final fit once the crinoline bands are completed. Mike has delivered the safety valves x 3. He has also finishing the rework of the front end regulator cams and valves at his Sydney workshop.
The next workday is Sunday the 17th of January, all welcome.
Alan Gardner.
Dec 21, 2009
Sunday 20 December 2009
Work is slowly progressing on the first and second bogies. The assembly of the spring and equalising beams was completed with surprising ease. The last of the keep plates and support bracings are now ready for fitting. All repairs have now been completed on the first bogie. The second bogie was jacked up and all of the keep plate bolts were removed to facilitate the lift of the frame off the wheels.
The boiler now sports the copper drain pipes that attach to the gauge glass assemblies. New and reconditioned cladding sheets are being fitted around the fire box area. The injector steam starting vales were cleaned down for assessment and found to be in serviceable condition. They will be fitted after the cladding is installed.
The next workday will be January the 3rd of January 2010. All welcome.
The boiler now sports the copper drain pipes that attach to the gauge glass assemblies. New and reconditioned cladding sheets are being fitted around the fire box area. The injector steam starting vales were cleaned down for assessment and found to be in serviceable condition. They will be fitted after the cladding is installed.
The next workday will be January the 3rd of January 2010. All welcome.
Dec 7, 2009
Saturday 5 December 2009.
Saturday 5 December 2009.
The rebuild of the bogies continued with most of the components now completed on the first. Ian has finished the machining of the replacement pins and Barry applied the top coats of black. The replacement manganese horn plates were fitted by Shaun while John and Kyle continued on with the assessment of the horn keep plates and associated parts. We are now hopeful that the first bogie will be completed before the years end. The experience gained will ensure the speedy rebuild of the next three bogies. The last outer bogies do not have air brakes fitted so this will make for much faster progress.
Mike Ridley came down from Sydney on Friday and he was able complete two straight days work. Mike has concentrated his efforts on the boiler cradle with the fitting of the reverser reach rods and he has now moved onto the power reverser mounting bracket. Mike is also looking at the mountain of electrical conduit with regard to the eventual re-wire.
We welcome two new members to our growing team. Paul Newland and Joseph Spinella cleaned out and re-organised the JLX box van adjacent to 6029. We now have room to work on the motion and valve gear. Paul and Joseph started to clean down the valve gear in preparation for crack testing.
The fitting of new sheet metal cladding to the boiler continues. The copper drain pipes for the gauge glasses and water column test cocks were bent up using the time honoured method of filling the pipes with sand before heating. Ian has taken the large bore copper pipes for the stoker system home for overhaul. When completed, the back head piping will be fitted in preparation of the final steam test.
The reach rods from the control handle to the front end throttle were assessed and given the usual grey primer clean up. Mike Reynell has been rebuilding the camshaft and main valves at home. Thanks to Malcolm for supplying the old maintenance manuals for the front end throttle. Mike advises that he will come down from Sydney for a few days and he intends to complete the final fit out of the front end throttle and sub assemblies.
Our next workday is Sunday 20 December.
The rebuild of the bogies continued with most of the components now completed on the first. Ian has finished the machining of the replacement pins and Barry applied the top coats of black. The replacement manganese horn plates were fitted by Shaun while John and Kyle continued on with the assessment of the horn keep plates and associated parts. We are now hopeful that the first bogie will be completed before the years end. The experience gained will ensure the speedy rebuild of the next three bogies. The last outer bogies do not have air brakes fitted so this will make for much faster progress.
Mike Ridley came down from Sydney on Friday and he was able complete two straight days work. Mike has concentrated his efforts on the boiler cradle with the fitting of the reverser reach rods and he has now moved onto the power reverser mounting bracket. Mike is also looking at the mountain of electrical conduit with regard to the eventual re-wire.
We welcome two new members to our growing team. Paul Newland and Joseph Spinella cleaned out and re-organised the JLX box van adjacent to 6029. We now have room to work on the motion and valve gear. Paul and Joseph started to clean down the valve gear in preparation for crack testing.
The fitting of new sheet metal cladding to the boiler continues. The copper drain pipes for the gauge glasses and water column test cocks were bent up using the time honoured method of filling the pipes with sand before heating. Ian has taken the large bore copper pipes for the stoker system home for overhaul. When completed, the back head piping will be fitted in preparation of the final steam test.
The reach rods from the control handle to the front end throttle were assessed and given the usual grey primer clean up. Mike Reynell has been rebuilding the camshaft and main valves at home. Thanks to Malcolm for supplying the old maintenance manuals for the front end throttle. Mike advises that he will come down from Sydney for a few days and he intends to complete the final fit out of the front end throttle and sub assemblies.
Our next workday is Sunday 20 December.
Nov 17, 2009
Sunday November 15 2009.
Work on the MHG support van is progressing well. We now have a decent workbench and tool storage. Pat the electrician has been beavering away behind the scenes installing power points and lights. The grinder, cupboards and bench drill have been installed and as a consequence of this we now can now actually work efficiently. Before we had the van we wasted countless hours setting up and packing away equipment every work day. Thanks to the efforts of all involved we can just plug in the power and start working.
As previously reported the four bogies are main focus of work. The years of grime and rust are now giving away to what resembles an almost a new bogie. Originally we were only replacing the worn mounting studs however when using the torque gun they were snapping like carrots. So all are now being replaced with new.
Our resident fitter, boilermaker, sheet metal, and generally good bloke Ian continues to work at home at what ever is asked of him. The cladding on the back head of the boiler has now started to progress forwards along the firebox area. As a consequence of this, the final fitting of copper pipe work has started. The labyrinth of small bore copper pipes is being annealed and assessed for condition and re fitting.
In general terms we are at the hard slog stage, and although the cleaning, assessing and painting is hard work, we are realising some very pleasing results. Having said that we can only do it with help and presently we have no shortage of tasks that are looking for willing helpers. No skills are necessary and on site tuition is available.
If you haven’t come along to a work day for some time or even if you are new to Project 6029, please come along, all welcome.
Our next workday is Saturday the 5th of December, again all welcome.
Alan Gardner
As previously reported the four bogies are main focus of work. The years of grime and rust are now giving away to what resembles an almost a new bogie. Originally we were only replacing the worn mounting studs however when using the torque gun they were snapping like carrots. So all are now being replaced with new.
Our resident fitter, boilermaker, sheet metal, and generally good bloke Ian continues to work at home at what ever is asked of him. The cladding on the back head of the boiler has now started to progress forwards along the firebox area. As a consequence of this, the final fitting of copper pipe work has started. The labyrinth of small bore copper pipes is being annealed and assessed for condition and re fitting.
In general terms we are at the hard slog stage, and although the cleaning, assessing and painting is hard work, we are realising some very pleasing results. Having said that we can only do it with help and presently we have no shortage of tasks that are looking for willing helpers. No skills are necessary and on site tuition is available.
If you haven’t come along to a work day for some time or even if you are new to Project 6029, please come along, all welcome.
Our next workday is Saturday the 5th of December, again all welcome.
Alan Gardner
Oct 21, 2009
Sunday 18 October,
The first of the four bogies is now starting to look like it is brand new ex-works. The brake cylinders have been re fitted and the many sub assemblies have had the usual three coats of paint. Some of the bushings and pins will need to be replaced. John continued with the strip down of the second bogie and we are hopeful that we can lift the bogie frame off the wheels on the next workday. The repaired lateral control springs should be back on site in the next few weeks.
Mike continued with the re fitting of the overhauled reverser reach rods that run down the drivers side of the boiler cradle. One of the last jobs for the day was to lift both of the long reach rods into position. Yes that’s correct we are starting to put it back together.
Since starting the project, we have had no workshop facilities on site. Thanks to the continued efforts of Barry, Stuart, Marc and Pat the electrician, we now have a mobile workshop. As a consequence of this we are now looking for a bar fridge(already found), kettle and seats.
Our next workday is Saturday 7th November 2009.
Alan Gardner
Mike continued with the re fitting of the overhauled reverser reach rods that run down the drivers side of the boiler cradle. One of the last jobs for the day was to lift both of the long reach rods into position. Yes that’s correct we are starting to put it back together.
Since starting the project, we have had no workshop facilities on site. Thanks to the continued efforts of Barry, Stuart, Marc and Pat the electrician, we now have a mobile workshop. As a consequence of this we are now looking for a bar fridge(already found), kettle and seats.
Our next workday is Saturday 7th November 2009.
Alan Gardner
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