Today, the hind unit brake cylinder piston cup seals were replaced with the new neoprene type. This was not an easy job as the new seals are very stiff and don’t squash down easily. Once the seals eventually slide into place the felt follower seals present another set of problems. Again after much grunting and pushing the tee type securing bolts were fitted into place securing the head to the cylinder . The push rods and subsequent pins will be final fitted on our next workday.
The brake system is in general terms, continuing at a good pace but the cab sub floor piping requires significant work. So much so the it has been decided to replace the drivers side cab sub floor sheet for two reasons. The first being that it has seen better days and the second being access to a very cramped space. The floor was cut into two sections to allow the brake stand and sub assemblies to be removed for assessment and repair. The grimy, rusted pipes only yielded after we applied heat with the oxy torch helped by hydraulic jacks. The four feed valves and many smaller fittings are now off site being rebuilt as home work and yes they are seized and full of that rusty grime.
The cabs steel sub floor is about four inches below the timber floor and supports many sub assemblies including a myriad of pipes, both steam and air. Much of the rust and grime in the area is a direct result of coal dust and over use of the cab hose. Maybe the manufactures knew this as a this would ensure the purchase of new locomotives for future sales. Oh well bad timing you might say as diesels were well into production when 6029 was new!
Our next workday (Saturday June 4) will see us continue around the cab sub floor area. Hopefully the new replacement sheet for the sub floor will be on site ready for fitting by then.
Alan Gardner
 |
May 25, 2011
Apr 19, 2011
Its been a while...
but we have not been resting on our laurels. In Sydney, the cab has been riveted back together, while in Canberra, the work has been continuing at the usual pace.
The cab has been riveted over 2 days, with help from Goodwin Alco's Steve Preston, Craig and Dave, along with the two Mike's and Malcolm. The days were very noisy, and it was good at the end of the day to see lots of bolts replaced by rivets. Photos will follow shortly.
In Canberra, the hind unit has again been getting some attention. There has been some abrasive blasting performed to clean up some areas, the rear draft package is back in, and I am sure that there has been more black paint applied wherever there was bare metal.
h
The boiler has also been getting its fair share of attention, with the crinoline bands bing refitted in preparation for some new boiler cladding. More info shortly.
Mike
The cab has been riveted over 2 days, with help from Goodwin Alco's Steve Preston, Craig and Dave, along with the two Mike's and Malcolm. The days were very noisy, and it was good at the end of the day to see lots of bolts replaced by rivets. Photos will follow shortly.
In Canberra, the hind unit has again been getting some attention. There has been some abrasive blasting performed to clean up some areas, the rear draft package is back in, and I am sure that there has been more black paint applied wherever there was bare metal.
h
The boiler has also been getting its fair share of attention, with the crinoline bands bing refitted in preparation for some new boiler cladding. More info shortly.
Mike
Mar 21, 2011
Sunday 20 March 2011
Now that the boiler cradle is well and truly in place the boiler itself has become the next stage in the critical path of assembly. In fact the Thursday before the workday also saw the use of a 80 ton mobile crane to lift the boiler into position next to the locomotive in preparation for the workday. The boiler was packed with timbers to give relative easy access to the foundation ring so the last of the broken ash pan mounting studs could be drilled out. This job went surprisingly well as upside down work was is never easy and after an hour of the usual grunting and groaning we were done. The lift itself was a bit of an anti climax as the boiler was lowered into position with ease.
With the boiler in place, and after a quick check for clearance, the expansion slides were fitted in preparation for the expansion brackets. They could not be bolted down as some of the studs will have to be replaced. The exhaust steam ball joint that attaches to the blast pipe was checked and it comes as no surprise that some major surgery will be required.
After lunch some of the guys were treated to a ride around the yard on locomotive 1210. It was a pleasant change from eating grinding dust. With all that out of the way, the team started to piece together the remaining crinoline bands. As the name suggest these bits are the frame work that holds the cladding sheet metal in place. Some of the lower parts of the bands are rusted out so new sections will be made as required.
Looking forward, and the next few months should see the cab returned to Canberra for final fitting. With the boiler and cab in place the steam pipes and fittings will be hooked up for the eventual steam test. We are asking for everyone to make that extra effort and attend the next few workdays as the big move is on. Come April, we see 6029 shunted into the large shed to facilitate the fit out of the lubrication system, cab floor and anything else that needs doing. We will also need all hands on deck to help clean up the large shed before 6029 moves in.
Alan Gardner
With the boiler in place, and after a quick check for clearance, the expansion slides were fitted in preparation for the expansion brackets. They could not be bolted down as some of the studs will have to be replaced. The exhaust steam ball joint that attaches to the blast pipe was checked and it comes as no surprise that some major surgery will be required.
After lunch some of the guys were treated to a ride around the yard on locomotive 1210. It was a pleasant change from eating grinding dust. With all that out of the way, the team started to piece together the remaining crinoline bands. As the name suggest these bits are the frame work that holds the cladding sheet metal in place. Some of the lower parts of the bands are rusted out so new sections will be made as required.
Looking forward, and the next few months should see the cab returned to Canberra for final fitting. With the boiler and cab in place the steam pipes and fittings will be hooked up for the eventual steam test. We are asking for everyone to make that extra effort and attend the next few workdays as the big move is on. Come April, we see 6029 shunted into the large shed to facilitate the fit out of the lubrication system, cab floor and anything else that needs doing. We will also need all hands on deck to help clean up the large shed before 6029 moves in.
Alan Gardner
Mar 20, 2011
Ok.... so we didn't expect this!
I don't need to say much... The pictures say it all! Hands up those that are impressed with the progress the team have made in the last month, and if you can, dig deep and help us finish what we have started... Donations are always welcome.
 |
| From Boiler in |
Mar 8, 2011
Saturday 5 March 2011
The first day of spring realized mild temperatures that were a welcome relief from the summer heat. The day started with the usual drill of running out of the power leads and a cup hot strong coffee.
The first job was to screw down the two large tension bolts that form part of the self adjusting pivots. They are designed to be pre-set at a tension which allows the pivot to self adjust for any wear. The adjustment of the screws required the combined effort of Paul, Tony and Andy utilizing four foot long pipe on the end of a four inch AF spanner. After about an hour of grunting and groaning both screws were at the required tension. For the record, a gap of 11/8" is called up on the manufactures drawing. The male pivots on both engine units had accumulated some minor surface rust and David soon cleaned off the offending iron oxide and applied a liberal coat of cylinder oil.
All this activity was leading to the project milestone of once again having the three major elements of the two engine units and the boiler cradle back together. Both the engine units were positioned to approximately the correct distance from each other. The boiler cradle was gradually lowered onto the engine unit’s, one end at a time. The end result of seeing the locomotive back together satisfied the crew to no end.
With the boiler cradle off the ground, the opportunity was taken to give the site an overdue clean up. The clean up will facilitate the long anticipated lifting of the boiler onto the boiler cradle. With only some minor prep work to complete it is anticipated that the boiler lift will take place in the next few weeks. This has only been made possible with the generous donations made recently by our project supporters, thanks to all who have contributed.
Our next workday is Sunday the 20th of March 2011
Alan Gardner
The first job was to screw down the two large tension bolts that form part of the self adjusting pivots. They are designed to be pre-set at a tension which allows the pivot to self adjust for any wear. The adjustment of the screws required the combined effort of Paul, Tony and Andy utilizing four foot long pipe on the end of a four inch AF spanner. After about an hour of grunting and groaning both screws were at the required tension. For the record, a gap of 11/8" is called up on the manufactures drawing. The male pivots on both engine units had accumulated some minor surface rust and David soon cleaned off the offending iron oxide and applied a liberal coat of cylinder oil.
All this activity was leading to the project milestone of once again having the three major elements of the two engine units and the boiler cradle back together. Both the engine units were positioned to approximately the correct distance from each other. The boiler cradle was gradually lowered onto the engine unit’s, one end at a time. The end result of seeing the locomotive back together satisfied the crew to no end.
With the boiler cradle off the ground, the opportunity was taken to give the site an overdue clean up. The clean up will facilitate the long anticipated lifting of the boiler onto the boiler cradle. With only some minor prep work to complete it is anticipated that the boiler lift will take place in the next few weeks. This has only been made possible with the generous donations made recently by our project supporters, thanks to all who have contributed.
Our next workday is Sunday the 20th of March 2011
Alan Gardner
Mar 7, 2011
Stop Press
It will come as a surprise to some, but Saturday saw the boiler cradle reunited with the loco units... More info soon, but certainly a milestone, and a sign of big things to come... Plus, not a mention of bogie's, well OK, just one!
More info, and more pics very soon!
More info, and more pics very soon!
Feb 21, 2011
Sunday 20 February 2011
4-8-4 + 4-8-4. Theses numbers may not be significant to an bystander but to the 6029 team it is a significant milestone. After 14 months of hard dirty work we rolled under the last of the four bogie. As we are now proficient with Garratt bogies an initial trail fit took place to double check for clearance and alignment . A wise decision, as we found a problem with the bogie in place. The two outer driving wheels had no contact with the rail head by about 25 mm. Further investigation revealed that the brake adjusting pull rods were not backed off and consequently the brakes where holding the driving wheels clear of the rail. Both four inch AF adjusting screws were backed off and on the second lowering the wheels settled back in the correct orientation. Sighs of relief all round and the crew was very happy to step back an enjoy the fruits of their labor.
The hind units headstock and coupling area was stripped down for assessment but not before a nest of wasps were evicted from their home inside the casting crevices of the automatic coupling. The project manger was stung by one wasp who took exception to being moved out. After the wasps finally got the hint, Andy and Howard removed the coupling carrier plate, brake isolating cocks and with some persuasion, the automatic coupling. The short brake pipes from the isolating cocks to the first barrel unions will be replaced as they were in poor condition. The step on the right hand side of the head stock was straightened and repaired and in truth it has not been on the locomotive for many years. The damage sustained was due to a rough shunt many years ago. The hind unit draft package friction springs are being manufactured new by the local spring manufacture. Once the replacement springs are delivered the draft package and automatic coupling will re-fitted to the hind unit headstock.
Now that the bogies are in place the "A" team of Kyle and John completed the fit out of the brake and flexible hoses connecting to bogies to the engine units. Some of the pins and bushes on the brake hangers were replaced as the team was not happy with the sloppy fit. The flexible lube lines received a final visual inspection and as predicted all were in the correct place and are a good fit.
As a direct result of today’s work, we are now in a position to start planning the lowering the boiler cradle onto the engine units. Both pivots will be preset in accordance with the manufactures drawings. The pivots will be cleaned for the last time and then on goes the boiler cradle. We can now move onto this vital stage as we have recently received a significant donation from some of our supporters. Thank you to everyone who has contributed and because of your efforts, the next couple of months will see 6029 back together in three distinct pieces as an articulated locomotive. This will make the way clear for lowering the boiler into the cradle in the next month.
So its all go systems go for some exciting times ahead.
Keep steaming
Alan Gardner
The hind units headstock and coupling area was stripped down for assessment but not before a nest of wasps were evicted from their home inside the casting crevices of the automatic coupling. The project manger was stung by one wasp who took exception to being moved out. After the wasps finally got the hint, Andy and Howard removed the coupling carrier plate, brake isolating cocks and with some persuasion, the automatic coupling. The short brake pipes from the isolating cocks to the first barrel unions will be replaced as they were in poor condition. The step on the right hand side of the head stock was straightened and repaired and in truth it has not been on the locomotive for many years. The damage sustained was due to a rough shunt many years ago. The hind unit draft package friction springs are being manufactured new by the local spring manufacture. Once the replacement springs are delivered the draft package and automatic coupling will re-fitted to the hind unit headstock.
Now that the bogies are in place the "A" team of Kyle and John completed the fit out of the brake and flexible hoses connecting to bogies to the engine units. Some of the pins and bushes on the brake hangers were replaced as the team was not happy with the sloppy fit. The flexible lube lines received a final visual inspection and as predicted all were in the correct place and are a good fit.
As a direct result of today’s work, we are now in a position to start planning the lowering the boiler cradle onto the engine units. Both pivots will be preset in accordance with the manufactures drawings. The pivots will be cleaned for the last time and then on goes the boiler cradle. We can now move onto this vital stage as we have recently received a significant donation from some of our supporters. Thank you to everyone who has contributed and because of your efforts, the next couple of months will see 6029 back together in three distinct pieces as an articulated locomotive. This will make the way clear for lowering the boiler into the cradle in the next month.
So its all go systems go for some exciting times ahead.
Keep steaming
Alan Gardner
Feb 7, 2011
Saturday February 5 2011
The last of the four bogies was the main focus of the days work. The team fitted the flexible lube lines in time for Ian to deliver the next two sets of Nathan four way lubricators. The completed bogie was then transferred behind the trailing engine unit in preparation for its installation. We had to pinch ourselves...yes we were there, all done. All four bogies are ready to grace the network metals again, well done team. The opportunity was taken to complete some long overdue housekeeping around the space occupied by the bogies for the past year.
Andy and Tony started the clean up around the hind engine unit and cylinders in preparation of the installation of the forth bogie. As predicted bucket loads of baked on cylinder oil and road grime are prevalent and we expect quite a few hours of toil here. The next couple of workdays should see this task completed with only the bogie to roll under.
As the bogie work is all but completed the boiler cradle leading pivot was the next job on the list. Graeme and Shaun fitted both halves of the very large bronze pivot castings. The reconditioned tension spring nuts were screwed down to the pre-set clearance. While we were working on the leading pivot, Marc and Paul removed the live steam ball joint that is situated just above the pivot casting. The two lube lines that supply oil from the mechanical lubricators were found to be completely broken off. The cavity that the ball joint sits in was completely block solid with congealed oil and again lots of crud was cleared away. Needless to say, the lube lines will be repaired to the usual standard and maybe the oil will again be delivered to where it is required.
The good news is that we are now almost ready to start the reassembly of the engine proper. The first job will be to lower the boiler cradle into position followed by the boiler soon after. Having said that, we now need to raise the funds to facilitate the crane hire. We are asking for everyone to chip in and in fact, $3,000 will see the mighty 60 class starting to look like the real deal again.
Our next workday is Sunday the 20th of February and if we get a good turn out of volunteers we will be almost ready for the big reassembly.
Alan Gardner
Andy and Tony started the clean up around the hind engine unit and cylinders in preparation of the installation of the forth bogie. As predicted bucket loads of baked on cylinder oil and road grime are prevalent and we expect quite a few hours of toil here. The next couple of workdays should see this task completed with only the bogie to roll under.
As the bogie work is all but completed the boiler cradle leading pivot was the next job on the list. Graeme and Shaun fitted both halves of the very large bronze pivot castings. The reconditioned tension spring nuts were screwed down to the pre-set clearance. While we were working on the leading pivot, Marc and Paul removed the live steam ball joint that is situated just above the pivot casting. The two lube lines that supply oil from the mechanical lubricators were found to be completely broken off. The cavity that the ball joint sits in was completely block solid with congealed oil and again lots of crud was cleared away. Needless to say, the lube lines will be repaired to the usual standard and maybe the oil will again be delivered to where it is required.
The good news is that we are now almost ready to start the reassembly of the engine proper. The first job will be to lower the boiler cradle into position followed by the boiler soon after. Having said that, we now need to raise the funds to facilitate the crane hire. We are asking for everyone to chip in and in fact, $3,000 will see the mighty 60 class starting to look like the real deal again.
Our next workday is Sunday the 20th of February and if we get a good turn out of volunteers we will be almost ready for the big reassembly.
Alan Gardner
Jan 18, 2011
16-17 January 2011.
Our first workdays of 2011 got off to a good start as for once it wasn’t raining in Canberra. Large puddles of water were still prevalent but at least the forecast was for a fine and sunny weekend.
The object of the weekend was to install the third bogie(hind inner) under the hind unit. Andy and Tony continued to clean up the hind unit bogie pivot and sub assembles to facilitate the final fit of the bogie in question. No surprises here except for more coal fines in the frame casing cavities. This area directly below the coal screw conveyer and bunker so we guessed that there may have been some overflow when 6029 was being filled up for its runs. The final fit out of the bogie consumed significantly more time than we estimated as the project manger couldn’t work out the difference between left and right. As a result of this three attempts were made to fit the pedestal keep plates, third time lucky hey!
Paul stripped down the hind unit draft package(the big spring that absorbs the in train buffing forces) on the hind unit and as usual more road grime was present. The bottom retaining plate holding the draft package in place was cleaned down and crack tested with no issues identified. However the ¾" nuts were almost non existent from the effects of rust...Replacement nuts and bolts have now been ordered.
At 16:00 hrs on Sunday the inner hind bogie was lowered into position will little bother or fuss although the hot and tired crew were ready for a well earned drink and pat on the back.
Alan Gardner
While this was happening in Canberra, the cab was again receiving attention at Eveleigh, with more new panels being fitted. In one of the best turnouts we have had for a long time, Mike, Mike, Ron and Malcolm were onsite for the day. Lots of hands made light work, allowing the new roof panels to be trial fitted and they are a surprisingly good fit. The roof is made in three sections and are yet to be trimmed and welded together, but there is most certainly light at the end of the tunnel.
By the end of the day, all the panels that make up the sides of the cab had been refitted and we had even managed rehang a door with new hinges...It wont be long now and we can rivet it all back together.
The object of the weekend was to install the third bogie(hind inner) under the hind unit. Andy and Tony continued to clean up the hind unit bogie pivot and sub assembles to facilitate the final fit of the bogie in question. No surprises here except for more coal fines in the frame casing cavities. This area directly below the coal screw conveyer and bunker so we guessed that there may have been some overflow when 6029 was being filled up for its runs. The final fit out of the bogie consumed significantly more time than we estimated as the project manger couldn’t work out the difference between left and right. As a result of this three attempts were made to fit the pedestal keep plates, third time lucky hey!
Paul stripped down the hind unit draft package(the big spring that absorbs the in train buffing forces) on the hind unit and as usual more road grime was present. The bottom retaining plate holding the draft package in place was cleaned down and crack tested with no issues identified. However the ¾" nuts were almost non existent from the effects of rust...Replacement nuts and bolts have now been ordered.
At 16:00 hrs on Sunday the inner hind bogie was lowered into position will little bother or fuss although the hot and tired crew were ready for a well earned drink and pat on the back.
Alan Gardner
While this was happening in Canberra, the cab was again receiving attention at Eveleigh, with more new panels being fitted. In one of the best turnouts we have had for a long time, Mike, Mike, Ron and Malcolm were onsite for the day. Lots of hands made light work, allowing the new roof panels to be trial fitted and they are a surprisingly good fit. The roof is made in three sections and are yet to be trimmed and welded together, but there is most certainly light at the end of the tunnel.
By the end of the day, all the panels that make up the sides of the cab had been refitted and we had even managed rehang a door with new hinges...It wont be long now and we can rivet it all back together.
Jan 11, 2011
What happens when an armament fitter gets interested in steam?
Ian Senini has outdone himself with his latest project.... Take a look at the wonderful job he has done on the mechanical lubricators for the Garratt!
He has transformed the old, neglected lubricators into what I suggest is easily better than new condition.
Have a look at the before pictures, and compare them with the after... You will see what I mean! And then look at how complex they are... Every output is an individually metered, self contained pump, and Ian has rebuilt every one...
Well done Ian!
He has transformed the old, neglected lubricators into what I suggest is easily better than new condition.
Have a look at the before pictures, and compare them with the after... You will see what I mean! And then look at how complex they are... Every output is an individually metered, self contained pump, and Ian has rebuilt every one...
Well done Ian!
Subscribe to:
Posts (Atom)