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Post by Deleted on Jan 14, 2011 21:42:23 GMT
Oh God don't talk about Jordan and her cronies , I do a lot of work at Bray studios and lets just say that this was a base for their somewhat crazy plans. Now it's just Peter and the studio owner who has ruined the studio due to his plans to develop it for housing. Luckily locals have now put paid to that with various actions. Oh and Jordan ala Katie wouldn't know the first thing about making films....-  Pete |
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Post by Deleted on Jan 16, 2011 18:22:21 GMT
Good evening guys Last time I said I would be making the hinges next but I had forgotten that I needed to finish the axlebox covers first....lol Pic127 There are eight covers so I decided to do the machining in batches of four. Here the first four are having two No.43 holes drilled just inside the scribed lines marking out the oil way slot. Attachments:
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Post by Deleted on Jan 16, 2011 18:26:15 GMT
Pic128
With both sets of four covers drilled the drill bit was then changed for a 3mm slot drill, I then machined closer to the lines , finishing with needle files.
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Post by Deleted on Jan 16, 2011 18:28:52 GMT
Pic129 The finished covers with oil way blocks , of which one is left out of slot to show detail. Now that I'm back on track tomorrow I'll do the hinges.... Er I hope so.. Pete Attachments:
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Post by Deleted on Jan 16, 2011 18:30:31 GMT
Forgotten picture for pic128....lol Attachments:
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Post by Jim on Jan 17, 2011 4:11:48 GMT
As always lovely work Pete. I couldn't agree more on the question of 'smaller' being better that 'bigger' scale wise. I have a 'bigger' problem with the lubricators on Boadicea which I hope will be reduced once painted and with correct actuating arms.
Jim
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Post by Deleted on Jan 17, 2011 16:12:24 GMT
Ok so before I could fabricate the oil block lids I first needed to solder the blocks to the oil trays. Pic129 The oil trays were soldered using soft solder so I had to be careful during attaching the blocks. I first aligned the blocks by fitting the axlebox covers in place and then using superglue stuck each one to it's oil tray through the slot to ensure it was in the right place. Next the tray was held in a vice and steel blocks were placed either side to act as heat sinks, I also put a small piece of thermo block on top to help with this. Using a gentle heat the blocks were all soldered in place. Attachments:
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Post by Deleted on Jan 17, 2011 16:15:26 GMT
Pic131 The finished tray, the oil way hole has been drilled through into the tray and a small piece of self adhesive felt has been cut to size and placed in the tray ready for the oil at a later date Attachments:
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Post by Deleted on Jan 17, 2011 16:20:33 GMT
Pic132 I wanted to add the small lip that hangs over the block so after first fitting the hinge in place to mark out where the lip started the hinge was then held in a vice as shown. I had already shaped some steel bar to the profile of the block, using a small length of brass rod to protect the hinge the vice was tightened. I then used a small hammer to form the lip, after this picture was taken the lip was trimmed to size while still held in the vice. Attachments:
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Post by Deleted on Jan 17, 2011 16:24:56 GMT
Pic133 The finished article, later I need to replace the rivet used temporary until I can purchase some 3/64th stainless pins as to Don's instructions. I still have the other lids to make which I shall finish now. I have to say there was a lot of work involved in doing these little bits , probably why I've put it off for so long.. More soon.. Attachments:
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Post by Deleted on Jan 23, 2011 19:49:45 GMT
Good evening guys Over the last few days I've been working on both the spring hanger and brake hanger brackets. Neither are yet finished but thought I'd update now or I'd have a lot to upload later. First the spring hanger brackets, these are simple items made from right angle steel, drilled and filed to shape. There are 16 for the tender and 4 for the loco, I decided to do all of them together as it's easier, I also did a few spares just in case. First I made a jig for both drilling and filing, this started as 1"x1"x1/8th steel right angle which was drilled and then filed to shape. This was then heat treated to dull red , dipped in oil and left to cool , polished, heated again to a yellow colour for tempering and left to cool at room temperature. Pic134 Here is the finished pattern test fitted to the frames to check all is well. The pattern is oversized to allow the correct size right angle to fit inside it, of course the pattern had to be machined in it's corner to square it up to allow this. Attachments:
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Post by Deleted on Jan 23, 2011 20:00:46 GMT
Pic135 First job was to machine some right angle down to 3/4x9/16th, I had nothing close to this so had to use the same material that was used for the jig. I machined two lengths both of 8" to this size, I then machined the corner to both make it square ( steel right angle tapers from middle to edge) and reduce the thickness from 1/8th to 3mm as to drawing. With this done the pattern was held in the machine vice with the angle trapped to it. The three 1/8th holes taken from the drawings where drilled first and the outline was scribed, this was done 11 times along both sections of angle thus giving me 22 brackets. Attachments:
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Post by Deleted on Jan 23, 2011 20:09:43 GMT
Pic136 With the frame holes drilled and the shape marked the angle was then turned over for the other angle to be drilled and scribed. Here the No.22 hole for the spring hangers is being drilled , to ensure this was inline with the 3 holes on the other face the pattern was located in place using 3 x 1/8th rivets and again held tight in the machine vice. Before separating the brackets I need to machine a slot across the No.22 hole with a 3/16th ball nose cutter for locating the shock absorber, alas I discovered that I didn't have one so it's on order and I left the spring brackets for now. Attachments:
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Post by Deleted on Jan 23, 2011 20:18:39 GMT
Pic137 Whilst waiting for the ball nose I moved on to the brake hanger brackets. There are two types , these four are the middle and rear hangers. First a length of 3/4 steel was held in the 3 jaw and turned down to 21/32 . This was centred and drilled No.22, Don says to make a D bit and machine a 3/8 recess to a depth of 5/16. I decided to forgo that and use a 3/8 slot drill in the tailstock, it just means I have to accurately measure the 5/16 depth for each one. So the order of things was, No.22 hole, 3/8 recess to 5/16 and then part off at 7/16. This was done 4 times as shown in the picture. Attachments:
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Post by Deleted on Jan 23, 2011 20:24:07 GMT
Pic138 Last job for tonight was to drill the 4 holes to attach to the frames, these were done on the rotary table at 255,330,30,105 degrees as to drawing. The same settings will be used in a piece of flat steel to hold each hanger to have the next parts machined ,hopefully I'll cover that tomorrow. Pete Attachments:
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6233
Hi-poster
Posts: 156
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Post by 6233 on Jan 23, 2011 21:38:38 GMT
Looking good Pete, you will soon have it finished. I better get started on Tornado......
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Post by Deleted on Jan 24, 2011 18:35:08 GMT
Thanks Mark although I think I have a very long way to go yet... Pic139 To finish the machining of the brake hanger brackets I transferred the 4 holes to a piece of flat steel, drilled and tapped for 8BA. With the bracket thus held I could finish the 3/8 recess cutting directly out from centre. The final operation was to cut the flat section at 90 degrees to the recess 5/16 from centre, as shown in the picture. Attachments:
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Post by Deleted on Jan 24, 2011 18:38:58 GMT
Pic140 The finished item ready to be fixed to the frames. The holes have been drilled and tapped for 8BA bolts. Attachments:
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Post by Deleted on Jan 24, 2011 18:47:06 GMT
Pic141 The bracket was held in place using a nut and bolt, then squared to frame and holes transferred with transfer punch. Bracket was removed, holes drilled and bracket was then attached to back of frames as shown in the picture. Tomorrow I'll start on the front brake hanger brackets, I'll stay with the brakes until i receive the ball nose cutter at which point I'll return to the springs . Pete Attachments:
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Post by Deleted on Jan 28, 2011 21:32:28 GMT
The 3/16 ball nose slot drill arrived today so I got on with the spring hanger brackets. Pic142 Here the rotary table is being used to shape the bottom curve of the bracket. I turned up some alloy bar to an MT2 taper to fit the table with a spigot that has been drilled and tapped 2BA to hold the bracket. To stop the bracket from turning on the spigot the back edge was machined flat. The other face has already been roughly ground to shape ready to be fixed back to the jig for final filing. Attachments:
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