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Help us build the Front Bogie

Highslide JS

The front bogie of a steam locomotive is a 4 wheel, unbraked truck. It's job is to carry the weight of the front of the locomotive and control the entry into and out of curves. The building of the bogie is the next stage of building Hengist after initial frame assembly is complete. In order to build the bogie, we will need to procure the following components.

The photo above shows the front bogie from 71000 Duke of Gloucester in a partially stripped condition. The central slide can be seen - the pipes are grease feeds from the grease nipples on the left side of the bogie stretcher. The axlebox guides and their manganese steel liners can be seen. The side check gear spring is just visible.

The manufacture of the bogie will be broken into 3 phases :

  • Phase 1 - Manufacture of the bogie frame and side check gear.
  • Phase 2 - Manufacture of the axles, axle cannon boxes and fitting of tyres to wheels. Assembly of the wheels and axles.
  • Phase 3 - Manufacture of the springs and spring cradle. Installation of lubrication system.

For phase 1 of the bogie construction we are aiming to complete the bogie frame and its associated components. We have a number of components in stock and a number of components are being manufactured.

Click on the images below for a larger pictures.

Bogie Stretcher Casting
The bogie stretcher casting is the central 'skeleton' within the bogie upon which everything else is built. The 2 round areas are where the bogie bolsters engage; these carry the weight of the front of the loco. The central area is where the centre slide is located.
The part will be cast in a foundry and then will be taken to a machining shop for machining - these are the grey areas on the drawing

Casting - £8,500 - casting sponsored
Machining - £5,000 - machining sponsored

Status - Order placed for pattern manufacture and casting
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Bogie Centre Slide
A pivot pin fastened to the underside of the locomotive frames engages with the central hole of the centre slide. The centre slide has the ability to move left and right on the stretcher casting but is restrained by centering springs. This ensures that when a locomotive enters a curve, the forces on the bogie wheel flanges are kept within limits. It also ensures that the loco is recentred after leaving a curve.
The slide is a casting which will require machining after casting.

Casting - £4,000 - casting sponsored
Machining - £2,200 - machining sponsored

Status - Order placed for pattern manufacture and casting
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A bush is required in the centre slide which the centre pivot engages in - Manufacture - £80
2 wearing plates are required for the central slide to operate on - £100 each
4 bolts are required for the plates - £25 each
Spring Pads
These are the spring pads that sit between the bogie stretcher and the central buckle on the leaf springs. The "pip" on the left hand pad is welded into the arm on the bogie frame stretcher.

2 off spring pads - £264 - £132 each Sponsored by member

Status - In stock
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Bogie Side Check gear
On the front and back of the bogie, there is the side check gear. This controls the movement of the bogie centre slide. For a full explanation of what is involved here, take a look at the bogie pages in the build section. Highslide JS
To complete the side gear, we need :

2 off Spindles @ £57 each - Sponsored by Member - In Stock
2 off Distance Pieces @ £82 each - the orange item. The inner ends of the spring rest here
4 off Spring Guides @ £450 each - the fawn item. The outer ends of the springs rest here
4 off Stops @ £52 each - the fawn item. These locate spring guide in the yellow beam arms

At the moment the design is not finalised in this area so we are not currently seeking sponsors for these items.
Beams - Centre Slide to Side Check Gear
The Centre Slide must be restrained in movement by the Side Check Gear and the springs. 2 substantial beams connect the 2 components. The beams (yellow in the drawing) are fitted in slots in the centre slide. As the centre slide tries to move, it moves the beam which compresses 2 of the springs (one fore, one aft)

2 off Beams @ £275 each

Status - sponsored
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Bogie Pivot
The pivot is bolted to the underside of the main frames into the Frame Stretcher for Bogie Pivot. This pivot then engages with the centre slide on the bogie.

Casting & Machining@ £1300 - Sponsored by Member - In Stock
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Pivot Collar and Locking Ring
Once the pivot on the locomotive frames has been engaged with the centre slide of the bogie, a 2 halves of a pivot collar are fitted and then a locking ring secures the pivot collar. These are fitted underneath the centre slide to prevent the bogie from disengaging with the pivot. There are 2 components

Pivot Collar - £300 - Sponsored by Member - In Stock
Locking Ring - £75 - Sponsored by Member - In Stock
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Here are the components part way through manufacture. Top is the locking ring. Middle are the 2 halves of the pivot collar that engage in a slot on the bogie pivot. Bottom is the securing bolt Highslide JS
Bogie Frames
2 bogie frames are bolted to each side of the central stretcher. These will require final machining and drilling for the various bolt holes and fixing holes

2 off bogie frames - In Stock
Frame machining and drilling, costs £TBD

Status - A CAD drawing is currently being created to assist with machining.
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Bogie Frame Stays
The front and rear of the frames are braced in position by 2 frame stays, 1 forward, 1 aft.

2 off bogie frame stays - In Stock
These require machining, costs £550 per stay

Status - Machining complete. In inspection.
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Axlebox Guides

8 axlebox guides are bolted to the bogie frames. These will allow the axleboxes to move vertically within the guides. Manganese Steel liners are bolted to the face of the guides and is the rubbing face for the axleboxes. Manganese steel is very hard wearing.

8 off axlebox guides casting - £3,200 (one pattern, 8 castings @ £400 each)
8 off axlebox guides machining - £9,600 - £1,200 each
8 off manganese steel liners @ £100 each
88 off nuts and bolt - £880 - £10 each

Status - Pattern complete. Sponsorship for all 8 castings received. Order for casting placed.

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Bogie Bolster Cups

2 bogie bolsters fitted on either side of the main frames at the front of the loco transfer the weight to the bogie via these bogie bolster cups. These are free to "float" on the top of brass pads fixed to the bogie stretcher casting

2 off Bogie Bolster cups £400 @ £200 each Sponsored

Status - Complete. In stock.

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Here are the completed bogie bolster cups. The right hand one is upside down and and, originally, a Ferobestos pad was fitted in the recess. This will be replaced by a Tufcot pad (in stock) that has similar charateristics to Ferobestos but without the asbestos. The Ferobestos/Tufcot pad provides a dgree of damping. Highslide JS

In 1959 to 1960, most of the Clans were fitted with BR Automatic Warning System. You can tell if it has been fitted by the presence of a protection plate behind the screw coupling on the front drawhook. Part of the installation was a new fabricated reciever stay as seen here between the lifeguards on 71000's front bogie (photo courtesy Michael Hughes from the BR Class 8 Steam Locomotive Trust). We will not be procuring the central joggled plate yet. Almost certainly, we will need to mount other signalling detection systems here such a TPWS so we will leave that decision until later. You could sponsor the stay for £660 or a monthly standing order of £55.

Front Bogie Frame Stay and Receiver Carrier - £660

Status - in stock

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Phase 2 tackles the wheels and axles. The axle and cannon boxes need to be manufactured. Tyres will be fitted to the wheels. Finally, the axles will be fitted to the cannon boxes and then the wheels will be pressed onto the axles. This work will be expensive and will need be contracted to an approved rail accredited supplier.

Axles
2 axles are required. The axle is a safety critical component and must be supplied by accredited suppliers. The axle has its smallest diameter in the centre and is not parallel throughout.

2 off axles @ £9,000 each
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Wheels
The bogie has 4 wheels and these are now in stock. Each wheel will require a tyre, another safety critical component.

4 off wheels - Sponsored by Member - In Stock
4 off Tyres - £7,200 - £1,800 each

The wheels will require machining and the tyres will need fitting to the wheels - costs £TBD
Highslide JS
After casting and the processes that go after it, the wheels have been heat treated. This consists of Heating and Soaking at a suitable temperature followed by cooling under conditions such that, after return to ambient temperature, the metal will be in a structural state closer to that of equilibrium.
The heat treatment was provided by Thermofax in Dudley, West Midlands who provided the treatment as a donation to the project. We are very grateful for their assistance.
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Axle Cannon Boxes
The cannon box is a single piece casting which comprises of 2 axle boxes at each end of the cannon box and a tube fixed to the axleboxes which rigidly holds the axleboxes in position. It is split horizontally to allow it to be assembled. The cannon box bearing was introduced by George Stephenson on the Locomotion. Because the driving axle was now enclosed, this provided the necessity for coupling rods to be developed. A set of taper roller bearings is fitted to each axlebox and the cannon box fixes the alignment of these bearings to each other. These will be expensive to produce as they are a critical component. The drawing shows half of a cannon box.

2 off axle cannon boxes - £ TBD
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This image is taken from the CAD model of the cannon box which our design team are working on. The part in the image is a steel casting. The ends of the cannon box where the axle ends emerge was sealed by a leather seal in the original design. We aim to update this design with modern seals and will be submitting our design to Timken for approval. Highslide JS

Phase 3 is the final phase and will involve the manufacture of the spring cradle and procurement of the leaf springs. The final task will be the installation of the bogie lubrication system. Oil for the centre slide and grease for the axle box guide liners.

Spring Cradle Plate
Under each of the "arms" of the bogie stretcher sits a laminated spring of 21 leaves. This is upside down and the ends rest in a spring cradle. The ends of the spring cradle have pins which sit in a cup on top of the axleboxes. The cradle acts a compensation or equalising beam and helps to ensure that a wheel does not become unloaded. We need to purchase 4 arms to make up 2 pairs.

Cost - £2,000 per plate - 4 required
Highslide JS
We are grateful to Michael Hughes from the BR Class 8 Steam Locomotive Trust for the reproduction of this photo which shows the bogie from 71000 Duke of Gloucester with the spring cradle fitted. The design is very similar to the Class 6.
In BR Days this component would have been forged using die blocks. We probably manufacture this by machining from a solid block of metal. Heat treatment will be required between rough machining and final machining.
Highslide JS
To complete the cradle, we need :

4 off Spring Brackets @ £220 each - these are the 2 inner brackets you can see on the drawing. The ends of the spring rest here
4 off Distance Pieces @ £200 each - these are the 2 outer brackets supporting the dome headed pin
4 off Pivot Pins @ £91 each - this is the dome headed pin facing downwards that will rest in a cup on the top of the axle box
4 off Set Screws to secure pivot @ £10 each
Springs
The bogie has 2 leaf springs, 1 per side. The top of the spring (as in the drawing) engages with a bearing spring pad which is fixed to the bogie stretcher casting

2 off springs - £ TBD
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Spring Links
4 spring links connect the ends of the leaf springs to the bogie cradle. The 4 on the left are for the bogie. At the same time we had the links for the driving wheels manufactured - these are on the right.

Status - In Stock
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Spring End Shoes allow the spring links to engage with the springs and the bogie cradle.

8 off Spring End Shoe - £1,900