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Post by Deleted on Sept 30, 2009 15:27:55 GMT
JB I did tell you that Helen Verral makes exceedingly good boilers. DJ I think I'm starting to get the hang of this caper! Who was it who said that revenge was a dish best served cold.....  This is straight out of the pickle, and given just a brass brush off. I'm quite pleased with it! I just put 3mmX1mm section silver solder inside the barrell, shaped to rest on the throatplate, and 'drew' it thru with the 35mm burner. The top of the barrel is where I wanted it! How I did the joint will remain a closely guarded secret between the boiler inspector and me.....   |
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Post by dickdastardly40 on Sept 30, 2009 18:15:36 GMT
I think I'm starting to get the hang of this caper! 'Many a slip twixt cup and lip' ;D Great work, look forwards to more. Al |
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Post by Deleted on Oct 1, 2009 18:59:57 GMT
Moving swiftly on......... Time for the inner firebox. The firehole is interesting, because the first one I made as specified was tiny, and completely unsuitable for my potentially arthuritic hands. Here is the first one: it fell out of the chuck whilst sizing it so there was a good excuse to make a bigger one!  Here is the second one in the making, much bigger!  Machined and flattened:  Fitted in the doorplate ready for rivetting to the wrapper:  I don't know how I ever found time to go to work....... JB |
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Post by Shawki Shlemon on Oct 2, 2009 10:24:44 GMT
Now that you have retired and found another job ( making boilers ) , once this prototype is completed and well as I expect , then you can start making them for sale , I bet that DJ will want to buy one from you . You are doing a great job, congratulation .
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Post by drjohn on Oct 2, 2009 11:57:01 GMT
... I bet that DJ will want to buy one from you ... Cheeky Shawki! ;D ;D but rather from JB than that moronic Australian boiler maker!!  DJ |
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Post by Deleted on Oct 2, 2009 15:44:56 GMT
OK, nearly there. Today's job was the 10g boiler tubeplate, and it involved bashing out the deepest flange (3/4") that I'd ever done. The words & music optimistically said "You may have to anneal it two or three times...." Most expensive ashtray I ever made!  Turning to correct diameter was a little iffy as the boiler end wasn't quite round.  Tube plate tapped in gently. The AUTOCAD template was very useful as the hole centres are shown as points.  Tube plate drilled and countersunk. All I have to do now is conjure up a 5/8" reamer and I can fit the tubes in the combustion chamber. Then it can be assembled and brazed up, hopefully sometime next week. I'll be taking orders after that......joking!  |
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brozier
Part of the e-furniture
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Post by brozier on Oct 2, 2009 15:50:10 GMT
Looking good. Surely you mean a 5/8" Drill?
You'll need a sloppy fit to give room for the Silver solder to penetrate.
Regards
Bryan
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Post by Deleted on Oct 2, 2009 15:54:31 GMT
Hi Bryan. Yes, I think I do need a reamer as the tubes are not perpendicular to the top plate and they emerge at about 45 degrees. A bit of 'magic' has to be wrought!
JB
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Post by mutley on Oct 2, 2009 16:21:58 GMT
A vernier caliper JB? This is boiler making......
Andy
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Post by Deleted on Oct 2, 2009 16:49:43 GMT
... I bet that DJ will want to buy one from you ... Cheeky Shawki! ;D ;D but rather from JB than that moronic Australian boiler maker!! DJ Blimey! Coming from DJ that's almost a compliment! |
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Post by baggo on Oct 2, 2009 17:50:03 GMT
Hi JB, looking good  The holes for the water tubes in the combustion chamber are a bit tricky. I got around it by using a template (drawn in CAD) with the elliptical outline of the tubes stuck to the shell. I drilled smaller holes and then carefully filed them out to slightly less than the correct size. Finally I put a reamer through both top and bottom of the shell to clean them up and make sure they were in line. You can always open them out slightly if the tubes are too tight.  John |
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Post by Deleted on Oct 2, 2009 18:16:57 GMT
Hi John (baggo), I think I will do something similar. As I'm only a poor old pensioner and too tight to buy a one-off reamer, I''ll exercise those long lost filing skills and fit the tubes manually.
That reminds me: one of my apprentice jobs was to create, by hand, a 3" hole in a piece of 1/2" steel plate, using a ratchet and post (I bet only a few people know about that!) and half-round files. They gave us a 3" plug gauge, and the test was it had to fall through the hole by its own weight.....
So this is quite easy then?
Ha Ha! I think not!
JB
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Post by dickdastardly40 on Oct 2, 2009 18:25:33 GMT
Might be able to lay my hands on a 5/8" H7 reamer JB, if you can wait until next tuesday for me to check!
Al
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Post by Deleted on Oct 2, 2009 18:31:56 GMT
Thanks Al, I can wait! Do you take one sugar or two?
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redmog
Part of the e-furniture
Not Morgan weather
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Post by redmog on Oct 3, 2009 6:50:30 GMT
To Bush or not to Bush.
Nice work JB.
I'm inspired to get on with mine when I can find
some 4 1/4" tube.
Are you going to fit bushes in the smokebox tubeplate
for the longitudinal stays?
Chris
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Post by Deleted on Oct 3, 2009 6:56:49 GMT
Good question Chris. Both ends are 10g, so plenty thick enough for my purposes. However, my friendly boiler inspector just sent me an email asking me if my drawings had been updated to show the new bushing requirements!
JB
EDIT. I don't wish to restart the debate, but I just re-read the examination and testing book (2008) and it says " Ensure that screw threads of fittings and their mounts are of adequate depth to maintain sufficient strength". so perhaps I'll just leave things as they are....
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redmog
Part of the e-furniture
Not Morgan weather
Posts: 461
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Post by redmog on Oct 3, 2009 9:05:49 GMT
Bush It.
JB.
This is just my line of thought!
For what little extra effort it involves, I like a bush.
More depth of clean thread.
Nice flat machined face to seal down onto.
Added strength.
Leaves a margin for error repair.
Go on - Bush It.
Chris
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Post by Deleted on Oct 3, 2009 9:27:26 GMT
Oh, all right then, you persuaded me far more easily than any regulation ever did! The dome bush appears to go in flat instead of being shaped to the boiler curve. This will look terrible unless there is some sort of cosmetic cover for it that I haven't found yet!
JB
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Post by Deleted on Oct 3, 2009 11:52:24 GMT
A vernier caliper JB? This is boiler making...... Andy I know it's a bit of bullshine Andy, but I have to get the centreline right, hence this little cardboard setup. As it happened the wrapper was slightly longer on one side, thus making the boiler lop-sided. I can imagine myself driving it round the track and being distracted by an out-of-position dome bush!  |
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Post by baggo on Oct 3, 2009 16:48:38 GMT
The dome bush appears to go in flat instead of being shaped to the boiler curve. This will look terrible unless there is some sort of cosmetic cover for it that I haven't found yet! There is a cast dome that goes over it John |
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