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Build Diary entries for June 2020

Here are the diary entries for this month. You can use the forward and backward links to see the next or previous months. Most photos taken before 2018 are small size. From 2018 onwards, most photos you see below will have a link to a full size image by clicking on the photo.

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Inverting the Frames
01/06/2020
  Highslide JS
  For the machining of the bottom face of the frames at Pattinson Brothers Engineering, the frames were placed on their side and returned to CTL Seal in this orientation. In preparation for the next phase of work, the frames needed to be turned through 90 degrees so that they were fully inverted. Today, Damien (on the controls) and Pete (out of view) from CTL Seal carefully rotated the whole assembly. The tricky bit is at the point of balance - the manoeuvre was completed smoothly and with no fuss. The next stage isto spin the assembly through 90 degrees and place the frames on the assembly bed to the right. Then the cast steel stretchers will be placed in position so we can check if the machining of the stretchers and the frames has ensured that the stretchers are sitting closely on the frames. If that check passes, we can started installing the fitted bolts to permanently connect the components.
   
Pony Truck Bolsters
01/06/2020
  Highslide JS
  The pony truck bolster castings have now been machined and wre photographed on the inspection bench. The weight of the rear of the loco is transferred to the trailing truck in a similar manner to the way that the weight of the front of the loco is transferred to the bogie. The pony truck bolsters are bolted with the dome downward s to the bottom of 2 large gussets that strengthen the rear of the frames and the hind beam. The domes engage in bolster cups which can move on the trailing truck frame. You can see the oval sliding surface on 71000's trailing truck here
   
Bogie Stretcher Machining (5)
01/06/2020
  Highslide JS
  Finally for today, here is a top view of the bogie stretcher. This will now move to an NC machine to have the circular recesses for the bogie bolster pads machined. The central area is where the bogie pivot centre slide will fit. 2 wear plates covering the central area are secured by the smaller bolt holes. 2 "V Strips" are bolted down using the 4 larger bolt holes on each side. These have a 60 degree chamfer on the face nearest the centre slide, corrresponding with a similar chamfer on the matching face of the centre slide. Therefore the centre slide is held down vertically but is free to move from side to side (while being restrained by the side control springs)
   
Fitting the Cast Steel Stretchers
08/06/2020
  Highslide JS
  On arrival at CTL Seal today, we found that the cast steel stretchers have been placed into the upside down frames. Here is John Hind from the Advanced Steam Traction Trust measuring the gap between stretchers and the frames. For 2 of the stretchers we are now assured that when the stretchers are tightened down onto the frames, the small remaining gap will close up. For the front stretcher (which is only a single pair of legs compared with 2 pairs for the other stretchers) there was a slight gap on one side. The stretcher was removed and we identified a slight burr that will need to be taken out. The next step is to fit the frame keeps to get the correct horizontal spacing and then tighten the stretchers down onto the frames so that the bolt holes can be drilled and reamed to size.
   
Fitting the Stretcher Bolts (1)
15/06/2020
  Highslide JS
  CTL Seal have started to fit the stretcher bolts which need to be a drive fit. Here is Pete from CTL Seal reaming out one of the holes after drilling out to undersize. Pete is using an adjustable reamer so he can make sure that the bolts will be a drive fit. The markings on the frame were the measure gap before we used a set of straps to pull the stretcher down on the the frames. This then closed the gap.
   
Fitting the Stretcher Bolts (2)
15/06/2020
  Highslide JS
  After the hole has been reamed its time to drive in the bolts
   
Hind Beam Gussets
15/06/2020
  Highslide JS
  Meanwhile, over in the fabrication shop are the 2 hind beam gussets. These reinforce the back end of the frame and transfer the weight of the rear of the locomotive to the trailing truck. The bolsters bolt on the bottom which is the left hand side of the left hand gusset. These are in the fettling area where they will be tidied up before transferring to the machine shop for the bolt holes to be drilled. In BritishRailways days, these were castings. As the shape lends itself to fabrication, we have fabricated them using full penetration welding.
   
Intermediate Rubbing Block
15/06/2020
  Highslide JS
  Also in the fabrication shop was the Intermediate Rubbing Block. This is bolted to the centre of the hind beam and faces backwards aligned with a similar rubbing block on the tender. The drawbar goes through the centre hole. Manganese liners have been welded to the curved plates and now need to be welded into place.
   
Trailing Feet
22/06/2020
  Highslide JS
  Most of the bolts that fit the cast stretchers to the frames have been installed. Pete has started work on the trailing feet which support the rear end of the trailing frame keep. The trailing foot has been pulled down hard onto the frames via the strap; the top 2 bolts are temporary bolts to hold things in place. The lower right hand bolt has been reamed out to final size and has been tapped in to check the fit. The bolts will be installed with the heads on the outside. 6 of the 12 bolts need to be longer as they need to go through both the frame plates and the frame extensions.
   
Rear Spring Hangers
22/06/2020
  Highslide JS
  These are the rearmost spring hangers part way through machining. This was a more challenging job as the design is specific to 71000 Duke of Gloucester and the lot 242 Clan Pacifics; no drawing was available in the Natuonal Railway Museum Archives. Therefore, we created our own drawing from measuring the spring hangers on 71000. These were then cast by South Lincs Foundry.
   
Centre Slide Machining
29/06/2020
  Highslide JS
  The bogie centre slide is now on its second machining stage. Here a 1 inch radius is being machined; the tool head will move downwards to complete the job. The 4 round bosses will need to be drilled for the oil lubrication pipes. Also, the reverse face from the bosses will have lubrication grooves machined into the surface.
   
Axle Centre Buttons
29/06/2020
  Highslide JS
  Into stock today are these axle centre marking off buttons. 2 are fitted into light drive holes in the frames either side of the axle and will be secured by a bolt. The small drill point on the other side of the button will be used as an alignment check to ensure that the axle centres are in a straight line. 2 are longer as they have to go through the thickness of the frame plates and the frame extension plates.