Completing a 3 1/2" Jubilee

[GWR 101]

The casting set included some lengths of Phosphor bronze bar to be used for the axle bearings which are twelve in total. Six were double flanged for the main wheels and six single flanged for the pony and bogie trucks. I decided to machine these in blocks of three as it makes holding easier, these can then be subsequently sawn and the ends machined to the correct length. A problem was encountered that some of the bars had casting blow holes, but fortunately with careful cutting and utilising a spare piece of PB the required number were obtained. The single flanged bearings were machined to the correct profile, the main bearings however were left as plain cubes the slots to be added later. The bearings were then centre drilled in preparation for subsequent drilling and reaming in the lathe.



   



The bearings were then centre drilled in preparation for subsequent drilling and reaming in the lathe.
An axle box being set up in the four jaw prior to drilling and reaming, the main axle blocks are plain sided at this stage the side slots to be machined later. It’s worth mentioning that there are numerous ways of sequencing these operations, I just use the approach that I feel most comfortable with.

  

Milling the side slots in the main axle boxes next. Regards Paul

[timb]

Good progress Paul, poor castings have been a real problem for me too, good that you could get around it!

Tim

[GWR 101]

Tim thanks, to be fair the blow holes were not apparent and as I had purchased them off the web at a much reduced price I was glad I could work round it. Regards Paul

[GWR 101]

Well 3 months have shot by, I have been earning credit points by various jobs (decorating) on a recently installed new kitchen. So have now managed some workshop time, the 12 axle boxes have been bored and also the wheels. Attention has now switched to the axles, I usually use silver steel but have opted for ground bar for this build. Main axles 3 x 1/2" diameter and Pony & Bogie trucks 3 x 10mm diameter, these were easily obtainable sizes and also keeps both the imperial and metric camps on side.

I know there are differing views on machining these but I tend to stick with the methods I was taught many years ago. So using a steady I am facing and centre drilling ready for machining between centres (chuck and centre to be precise). I am proposing to make the wheels a press fit, nothing against gluing I just prefer this method.


      



Regards Paul

[GWR 101]

As all six axles are now faced to length and centre drilled, I have decided to finish the slots in the main axle boxes before turning the axles for the wheels. The club standard specifies 3.281" for the back to back with a tolerance of +0 -0.016", so I am aiming for 3.277". I will allow a small amount of end float for the coupled wheels and slightly more for the drivers as I am not removing the flanges. Regards Paul.

[GWR 101]

I have finished the slots in the main axle boxes and they are a nice sliding fit in the horn blocks. I now need to file some radii into the sides of the slots to allow for opposite wheels to be able to move up and down independently. Then drill the oil holes and drill and tap for the 3mm rods for the suspension. The axles are a nice running fit so  hopefully I can then move onto fitting the horn blocks etc in the pony and bogie trucks. Regards Paul

[smallbrother]

Taking shape Paul. Good to see.

Pete.

[GWR 101]

Thanks Pete, hope you are ok. I have to get a move on as time is limited and as I stated previously it is a project started by my late father so there is an additional incentive to get it running. Stay safe and take care especially when out on the bike. Regards Paul

[GWR 101]

Horn stays machined today will try and get them drilled tomorrow. Then spring retaining plates, hopefully can then move on from the main axle boxes and finish the pony and bogie trucks. Regards Paul

[GWR 101]

Decided to machine the horn stays as a block (believe Roger calls this "parts on a stick", "in this case parts on a bar".)


 


All seem to fit nicely on the bars, so the next job is to cut 12 to length, screw the ends and fit into the axle boxes, that's tomorrows job. Its amazing how much time it takes to make these parts its a good job its a hobby as it would be difficult to make a living at it.!    Regards Paul

[GWR 101]

Decided to drill and tap the horn blocks in the main frame next. Twelve in total seemed to go fairly well, the stays are a good fit in the horn blocks so that should help the rigidity.




Will fit the plates bar and springs tomorrow. Regards Paul

[GWR 101]

Collected this today, tested to 200psi. which is twice working pressure. Apart from time constraints on this build, I have neither the knowledge, skill or equipment for this type of work so when needs must.   Regards Paul

[mbrown]

Lovely!

How do commercial builders keep the silver solder so neatly confined to the joints, especially around the stays? With my boilers, the flux runs all over the place and the solder follows it.... I expect my thread will show exactly what I mean when I start soldering.

I would love to be able to use less solder and not waste it, apart from the aesthetic pleasure of a boiler looking like yours.

Malcolm

[simplyloco]

Nov 1, 2021 19:32:42 GMT mbrown said:

Lovely!

How do commercial builders keep the silver solder so neatly confined to the joints, especially around the stays? With my boilers, the flux runs all over the place and the solder follows it.... I expect my thread will show exactly what I mean when I start soldering.

I would love to be able to use less solder and not waste it, apart from the aesthetic pleasure of a boiler looking like yours.

Malcolm

Be like Tolkien: become 'Lord of the Rings!'

[ettingtonliam]

Tippex!

[GWR 101]

Hi, not sure how they manage it. I have seen Tippex mentioned on here in several posts so assume that or something similar is used. I didn't see the process and never thought to ask, I was  just pleased with the finished boiler. As mentioned previously this process is way above my pay grade. Regards Paul

[uuu]

Watching Helen Verrall-Stait at an exhibition demonstration - she just seemed to have the knack of introducing solder at just the right moment, and only just enough for it to flash into the joint. Very satisfying to see.

Wilf

Edit - she also seemed to be able to do a lot in one heat up - OK it was a small boiler, but she would flip it over and carry on where I'd have been stopping to pickle up and figure out my next moves.

[GWR 101]

Having completed the main suspension I decided to revert back to the suspension on the Pony and Bogie trucks. The side restraints are held in place with 1/16" dia. rivets (36 in total), I decided to make a small drill jig to drill the holes in the side frames, then spot through to drill the PB side bars.

Whilst drilling the jig I managed to break the drill, breaking a drill of this size could be considered an accident !, however when I broke a second drill that's just down right careless. So with 72 holes to go I found another drill (the last one I had), it was at this point I realised that the drill press was not running fast enough so I increased the speed by two pulleys.

This proved satisfactory, the moral being that even after 60 years at this game you can still fall down on the basics.   Regards Paul

[GWR 101]

Phew, all 72 holes drilled and riveted up without any further "accidents".   Decided to switch to some lathe work so found some steel bar to machine the two eccentrics for the leading axle. I intend to only have one axle pump but will fit the second eccentric in case its needed in the future, I might use it to drive the cylinder oiling pump. Regards Paul

[GWR 101]

Decided that it might be preferable to make the eccentric straps before the eccentrics. So the next job is to machine the two castings that came as part of the set purchased off the web. Obviously I need to undertake some "fettling" before starting on any serious machining.




Regards Paul