The Diary of the Building of a 5" gauge Stirling Single

    

Completion of the build     Part 16
8th October 2019

Today was a day of easing parts to the right place particularly pipework when the boiler was back in position and all taking a long time.

The reverser arm was adjusted
The boiler filler pipe from the top of the axle pump was adjusted but kinked so may need to make another
The connections leading to the tender at rear of engine were made tight

BUT
that still leaves the whistle to be installed
the sight glass water gauge also
the pressure gauge
and
connecting up the pipes from the super heaters ....

9th October 2019

Not being prepared to put up with a kinked pipe feeding water to the boiler from the axle pump so  I decided to resurrect my pipe bender from the early 1980's when I was making my Sweet Pea locomotive.

It may look a bit rusty but it did do the job.

The design is from my head after looking as many designs on the WEB.

The NEW piece of pipe now fitted to the engine and boiler back in place.

The bends are much better and actually slightly more direct following the curve of the boiler. You should be able to see that there is very little space between the boiler and the top union of the axle pump

This piece of pipe is actualy hidden behind a piece of place work when the engine is in running order but for the Steam Test that part of the plate work will be left removed so that a finger on the clack can prove it is working as with cold water through it the clack will be cold !!
In the afternoon I concentrated on connecting up the whistle.

When completed the engine was run up on air at LOW pressure and all checked out well except for the regulator which was leaking at the rear. An application of gasket sealer is required !!
10th October 2019

1. the regulator does not operate  All sorted
2. Make the boiler door catch and fit Completed
3. Sort out the coupling to tender Completed
4. Fix chimney to smoke box Completed
5. Amend the fixing of the cover plate above oiler Completed
6. Sort out axle pump as will not fit under the boiler Completed
7. Provide the blower outlet in the smoke box Completed
8. Fit lugs on the side of the boiler where it will sit on the frames adjacent to the firebox  Not required boiler sits level
9. The main Painting Completed
10. Make up the Cab spectacles All sorted and glass fitted
11. Pipework to whistle    Completed
12. Pipework to axle pump -- Completed
13. Pipework to injector  Completed

and still to do !!!
1. Connect pipes from super heaters to the steam chests. Completed on 11th October 2019 see below
2. Seal up the bottom of the smoke box so that a vacuum can form to draw the fire Completed on 12th October 2019 see below
3. Pipework to to dummy whistle
4. Sight glass fitting need aligning and glass fitted Completed on 14/15 th October 2019 see below
5. Complete fitting of banjo to blower. Completed on 12th October 2019 see below
6. Install the injector water valve operating levers. Completed on 14th October 2019 see below
7. Check the bolts are tight holding the firebox grate.
8. Fit the fire door keeper. Completed on 15th October 2019 see below
9. Make up 4 Auto Drain cocks for the cylinders.
10. Make up a bung with 1/4" male to fit safety valve thread and the pressure test rig.
do more lining out !!!!

The gasket sealer was applied to the regulator and after a wait for the solvent to evaporate the two parts were brought together. After a further wait the parts were further tightened down and more waiting until fully cured..

The excess will be removed in due course.

A support for the whistle was made up from brass sheet and bolted into position to prevent the whistle bouncing around during the time the loco is being used.


11th October 2019

The excess of the sealant to the regulator was cleaned off.

The smokebox super heater pipes had to be connected up to the steam chest pipes. There is so little space in the smokebox that putting four fingers in two from each hand was a tight squeeze. After an hour I had succeeded is tightening both nut down without cross threading them.

Also the blast nozzle was checked for alignment and that of the blower outlet.

The check for leaked found a blocked pipe to the pressure gauge which was remade and now the Pressure gauge show the pressure of air when put in the boiler (less than 60PSI for safety)

When the regulator was opened I am pleased to report that the driving wheels did turn forwards and backwards speeding up as the regulator was progressively opened and conversely slowed when closed, thus a good step forward.

I still need to fit the blow down elbow and valve and the water gauge ..
12th October 2019

The smoke box must be sealed to ensure that a vacuum can be developed to draw the fire through from the furnace. As can be seen there is a lot of space to fill.
High temperature mastic has been used and I hope it does seal the smoke box !!!

Additionally today the drain down valve was put in the drain down location using Loctite 524. Additionally a support may be needed if the sealant does not hold it in position.

The banjo to the blower was also tightened up.
13th October 2019

I was able to borrow an endoscope, which had its own built in led light source, from a Radio Amateur friend and looking in the smoke box all looks sealed up well..

Then I took a look under the chassis and saw that the Blow Down pipe looked all ok all ok.
I needed to check that the axle pump worked so it was coupled up to the tender feed and also its bypass.

The photo shows that the pressure from the pump creates quick a display!!
14th October 2019

The on / off operator had to have its operating leaver attached. As I wished to have it pointing forward when open to ensure this was correct I removed the valve and set it fully open and the replaced it in the tender. I decided to use Loctite 603 to set it in position rather than a drill and pin.

The other operator was in the closed position and as it will not be used for the moment as I have only fitted one injector a blow down the pipe confirmed it was off !!
 		as
A view inside the smoke box using a tiny camera with LED lighting I was able to check that the holes around the pipes seem to be well sealed up!!
The water gauge fitting installed but the glass will follow after the Loctite 524 has cured!.

I checked the alignment using a steel bar machined to size.
15th October 2019

Water gauge glass installed. I have used the red line type as it is easier to see the water level.
The first stage of connecting up the dummy whistle. The union with 3/16"x40 was machined then the nipple silver soldered onto the pipe and the assembled and bent to shape then cut to length.
I decided to make up a very small tee junction part which would accept the 1/8" pipe and the 5/32" pipe of the original run to the whistle.

I nice piece of machining and silver soldering.

Slight adjustment had to be made to the route of the pipe to the whistle else it would have come through the front of the cab, even so I will need to make a small nick in the cab to make room to the dummy whistle steam pipe.

A very satisfying afternoon's engineering.
The latch to the fire door was refitted and the excess bolts cut off. The door was rehung with its machined pin.

Al in all a nice fit.
Using the endoscope which only bought yesterday I was able to see the problems with the fit of the ash pan. The sides were too tight on the boiler so I was able using pliers to bend the sides out just a little.

I found that the keeping pin supplied  previously was too tight a fit so I had a piece of 3/16" mild steel rod which I machined a point  on the end of 10 degrees, measured it to length and silver soldered a piece of hex bar onto the pin.

The camera picture shows the exit of the keeper close to a piece of pipe, which will be adjusted so that it does not rub.

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