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Build Diary entries for October 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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Hornguide Machining Day 14
  Highslide JS
  Hornguide machining continues at a steady pace. Today, Luke from CTL Seal and Geoff discuss the machining of a small radius on the edge of the hornguides. Luke has the cutter in his right hand.
Exhaust Port Machining
  Highslide JS
  Hornguide maching is now complete so the frames have been turned through 90 degrees so that they are upside down. The final job on the machine is to clean up the area where the exhaust steam manifold meets the frame so that there is a smooth transition in this area. Photo by Tom Wade
Hornguide Machining Day 18
  Highslide JS
  The machining of the hornguides on the frames is nearly complete. We expect that the frames will be back in the machine shop on Wednesday. Today we finished cleaning up the exhaust ports on one side so Luke lifted the frames and turned them through 180 degrees so that he could get to the other side. This is half way round
Pony Truck Wheels cast!
  Another step forward in the building of 72010, Hengist. Sam Edwards from Boro Foundry in Stourbridge, West Midlands has reported that both pony truck (or trailing truck) wheels were cast on Monday 12 October. They are left in the mould overnight before they are knocked out and then left to cool down. You can see a short video of the casting by clicking on this link.
Bogie Pipework Fittings
  Highslide JS
  Ian (not your web site manager!) is one of our members and has a home workshop. He's kindly volunteered to manufacture the pipework fittings we need for the bogie. The original pipework design used a flared pipe end similar to that you would see on a car brake pipe. These were prone to breaking so, in the late 1950s, this was changed to a turned, coned pipe fitting secured by a nut. Here is one of the nuts being turned in Ian's lathe.
Front bogie progress.
  Highslide JS
  Work continues on the front bogie parts, pictured is the front bogie centre slide on one of the CNC machines at CTL Seal today..
Front Buffer Beam Update.
  Highslide JS
  Since the main frames have been returned to the assembly shop after the horn guide machining, attention has now turned to the front buffer beam assembly with lots of activity in this area today.
Buffer Beam Assembly Continues
  Highslide JS
  Work continues on the front buffer beam. The top of the buffer beam is towards the photographer with the buffer beam itself face down on the trestles. The drawhook goes through the circular plate in the centre. The complicated bit will be the building up of the 4 triangular gussets that sit either side of the frames. Currently these are in separate pieces and will need welding to assemble. You can see the 4 flange plates for the smaller, inside gussets either side of the the circular plate. Temporary bolts are being used for initial assembly; these will be replaced by rivets. Photo by Bob Ife
Hind Beam Gussets
  Highslide JS
  The hind beam gussets are large fabrications that are bolted to the end of the frame extensions and to the hind beam. They strengthen this area and also transmit loads at the rear of the engine to the pony or trailing truck through dome shaped bolsters. Originally, the gussets were steel castings; however we have fabricated them using modern welding techniques. Most machining is complete - here one of the gussets is on its final machine stage on CTL Seal's 3m CNC Elga machine. The job is to machine the boss on the right which is the bottom face of the gusset; the boss engages with a recess in the pony truck bolster. Photo by Jamie Black