Build Diary entries for March 2025

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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Spring Beam Welding
03/03/2025
	Welding is now complete on the pony truck spring beams. The spring beam has been moved to the machine shop for the manganese steel liner pads to be machined down to obtain the correct cross beam width. One of the beams has been lifted into the machining station ready to be clamped down to the bed. The red tinge in the photo comes from 2 sources. There was a radiant heater to the right as the machine shop was cold today. Also some of the red tint comes from the dye used in non destructive testing of the welds.
Coupled Wheel Progress
04/03/2025
	Today, Hengist's inspection team visited William Cook Cast Product Ltd to witness Magnetic Particle Inspection and Ultrasonic testing of 2 of our 6 coupled wheels. The testing was satisfactory and the wheels will now be shipped to Ada Machining Services for machining. Machining is primarily for the axle and crank pin bores; also on the diameter of the wheel. The ribs that can be seen on the spokes are where the balance plates will be fitted. The space between the plates will be filled with calculated weights of lead.
Coupled Wheel Progress (2)
04/03/2025
	This picture shows the height of the wheel. When fully machined the wheels will be 5 feet 8 inches - 1.727 metres - in diameter. When the tyres are shrunk on, the wheels will be 6 foot 2 inches - 1.88 metres - in diameter.
Riveting (1)
07/03/2025
	This weekend saw a major riveting session by Varley Boilers. The hind beam, trailing spring hanger brackets, brake hanger brackets and front lifting eye pads were riveted. A lot of the riveting was challenging as access was difficult. In the photo, the central intermediate rubbing block is being riveted to the hind beam and dragbox. An air driven "jammer" has to be used on the inside of the hind beam. The jammer is being locked in position before John can start riveting.
Riveting (2)
07/03/2025
	The rivets are heated to white hot in a hearth
Riveting (3)
07/03/2025
	Riveting the inside of the trailing spring hanger bracket was awkward. Te rivet was inserted from below and held in position with some tongs while an air jammer was positioned below. Then the rivet head could be formed. Dealing with the rearmost rivet on the inside was especially tricky
Riveting (4)
07/03/2025
	With everything in position, the rivet could be formed.
Pony Truck Spring Beams
07/03/2025
	Welding of the manganese steel liners and spigots to the pony truck spring beam is complete. They will next go to inspection. If that passes, we will need to get the painted.
Valve Cylinder/Steam Chest Core Box
11/03/2025
	Up in Scotland, Tony has completed all of the sections for the Valve Cylinder/Steam Chest Core Box. The corebox will be used to create 2 halves of a cylinder of sand which will form the air space in the cylinder. The central part is the steam chest where live steam enters. The gaps are for "loose pieces" which will also form the exhaust port passages. For a full explanation, go to the Construction tab above and follow Build >> Main Cylinders
Coupled Wheel Machining
14/03/2025
	Our coupled wheels have now been transferred to ADA Machining Services, a subsidiary of William Cook Holdings for initial machining. Here initial machining will take place with the final machining taking place when the wheels are assembled by an approved wheelset assembly company. In the photo, the wheel is on a vertical boring machine with the edge of the rim being machined.