THE ORIGINORIGINALAL MMAGAZINEAGAZINE FOR MODEL ENGINEERS ❖❖
Vol. 226 No. 4654 18 - 31 December 2020
Join our online community www.model-engineer.co.uk Index to volume 225 Christmas TTaleale PP22 Frames
COVER FEAFEATURETURE
ENGINEERING GROUP LBSC and TToyoy TrainsTrains £4.20
Published by MyTimeMedia Ltd. Suite 25S, Eden House, Enterprise Way, Edenbridge, Kent TN8 6HF www.model-engineer.co.uk 41 24
SUBSCRIPTIONS UK - New, Renewals & Enquiries Tel: 0344 243 9023 Email: [email protected] USA & CANADA - New, Renewals & Enquiries Tel: (001)-866-647-9191 REST OF WORLD - New, Renewals & Enquiries Tel: +44 1604 828 748 Email: [email protected] Vol. 226 No. 4654 18 - 31 December 2020 CURRENT AND BACK ISSUES Tel: 01795 662976 Website: www.mags-uk.com EDITORIAL Editor: Martin R Evans Tel: +44 (0)7710 192953 8 SMOKE RINGS 26 MAKING A STAND THAT News, views and comment on Email: [email protected] WILL MAKE YOUR MODEL Assistant Editor: Diane Carney the world of model engineering. STEAM ENGINES PROUD Club News Editor: Geoff Theasby Luker lines his locos up on ledges. 9 HOT AIR TOY LOCOMOTIVES PRODUCTION Roger Backhouse takes LBSC 29 INDEX TO VOLUME 225 Designer: Yvette Green back to his childhood. Illustrator: Grahame Chambers Retouching Manager: Brian Vickers 33 150 YEARS OF THE QUARRY Ad Production: Andy Tompkins 12 GRASSHOPPER HUNSLET DYNASTY HAULAGE ENGINE Mark Smithers celebrates 150 years of one of ADVERTISING Stewart Hart makes a model of a haulage the best known small locomotive manufacturers. Advertising Sales Executive: Angela Price engine displayed in the Manchester Email: [email protected] Museum of Science and Industry. 37 GARRETT 4CD TRACTOR MARKETING & SUBSCRIPTIONS Chris Gunn takes his tractor to its first Subscription Manager: 16 BOOK REVIEW rally and irons out a few issues. Beth Ashby Martin Ranson reviews Ceramic Burners for Model Steam Boilers by Alex Weiss. 41 PETROL ENGINE AND MANAGEMENT ALTERNATOR SETS Group Advertising Manager: Rhona Bolger Email: [email protected] 17 WORM AND WHEEL Jon Freeman investigates the design of efficient Chief Executive: GEARING IN CLOCKWORK petrol-electric locomotive traction systems. Owen Davies MECHANISMS John Moorhouse explains the use of 44 SHOWCASE 1 worm gears in clocks and automata. Terry Phelps's ⁄8th scale Morgan 'Grand Prix' Three Wheeler. 20 CAVALRY SWORD James Wells makes a half scale cavalry 45 P2 LOCOMOTIVE FRAMES © MyTimeMedia Ltd. 2020 sword for a full scale brigadier. Graham Langer follows the design of the frames All rights reserved ISSN 0026-7325 for new-build locomotive Prince of Wales. The Publisher’s written consent must be obtained before any part of this publication may be reproduced in any form whatsoever, including photocopiers, 22 XMAS TALE and information retrieval systems. All reasonable care is taken in the Rafe Shirley finds his rest disturbed 48 A NEW GWR PANNIER preparation of the magazine contents, but the publishers cannot be held legally by an unexpected visitor. Doug Hewson embarks on a mission responsible for errors in the contents of this magazine or for any loss however arising from such errors, including loss resulting from negligence of our staff. to improve LBSC’s half century old GWR Reliance placed upon the contents of this magazine is at reader’s own risk. 24 THE BARCLAY WELL Pannier Tank design. Model Engineer, ISSN 0026 - 7325 (USPS 24828) is published fortnightly by TANKS OF THE GREAT WAR MyTime Media Ltd, Suite 25S, Eden House, Enterprise Way, Edenbridge, Kent, TN8 6HF, UK. The US annual subscription price is 136USD. Airfreight and Terence Holland describes the 0-6-0 version 50 CLUB NEWS mailing in the USA by agent named World Container Inc, 150-15, 183rd Street, of his 5 inch gauge Barclay well tank. Geoff Theasby compiles the latest from Jamaica, NY 11413, USA. Periodicals postage paid at Brooklyn, NY 11256. US Postmaster: Send address changes to Model Engineer, World Container model engineering clubs around the world. Inc, 150-15, 183rd Street, Jamaica, NY 11413, USA. Subscription records are maintained at DSB.net Ltd, 3 Queensbridge, The Lakes, Northampton, NN4 5DT, UK. Air Business Ltd is acting as our mailing agent. THE ORIGINALORIGINAL MMAGAZINEAGAZINE FOR MODEL ENGINEERS ❖❖
Vol. 226 No. 4654 18 - 31 December 2020
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Join our online community www.model-engineer.co.uk Index to volume http://twitter.com/ 225 Christmas TTaleale modelengineers PP22 Frames ON THE COVER...
COVER FEAFEATURETURE ENGINEERING GROUP A hot air toy train set made by Ernst Plank of Nuremburg LBSC and ToyToy TrainsTrains £4.20
1 Front Cover 4654.indd 1 04/12/2020 09:53 (photograph ©Alex Prochek 2020). www.model-engineer.co.uk 3 Bringing British industrial history to life
Master Boiler Maker - Alan ‘Rivet Lad’ McEwen
When Master Boiler Maker and author, Alan McEwen was a young sprog, he loved banging and hammering on rusty old boilers; now that he is an old hog, he just prefers others to bang and hammer! Alan McEwen’s Boiler Making adventures and also ‘potted histories’ of several Lancashire and Yorkshire Boiler Making fi rms, can be read in RIVET LAD - Lusty Tales of Boiler Making in the Lancashire Mill Towns of the 1960s. The book is crammed with ‘hands on’ technical information of how Lancashire, Locomotive, Economic, and Cochran Vertical boilers were repaired over 50 years ago. The book’s larger-than-life characters, the hard as nails, ale-supping, chain-smoking Boiler Makers: Carrot Crampthorn, Reuben ‘Iron Man’ Ramsbottom, Teddy Tulip, genial Irishman Paddy O’Boyle, and not least Alan himself, are, to a man, throw-backs to times gone by when British industry was the envy of the world.
Alan McEwen’s fi rst RIVET LAD book: RIVET LAD – Lusty Tales of Boiler Making in the Lancashire Mill Towns of the Sixties published September 2017 is now priced at £25 plus £3.00 postage and packing to UK addresses. Alan’s second RIVET LAD book: RIVET LAD – More Battles With Old Steam Boilers was published in September 2018. Now priced at £25 including postage and packing to UK addresses.
BOOK BUNDLE SPECIAL OFFER Both RIVET LAD books can be purchased together for £40 plus £5 postage and packing to UK addresses. To place an order please telephone 01535 637153 / 07971 906105. All our books can be ordered on our website www.sledgehammerengineeringpress.co.uk or email: [email protected]. Overseas customers contact Sledgehammer by email for postage costs. We accept payment by debit/credit card, cheques, cash and postal orders made out to SLEDGEHAMMER ENGINEERING PRESS LTD. World From Rough Stones House, Farling Top, Cowling, North Yorkshire, BD22 0NW.
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Calls are charged at the same rate as standard UK landlines and are included as part of any inclusive or free minutes allowances. There are no additional charges with this number. Overseas calls will cost more. Merry Christmas! Everyone here at Model Engineer would like to wish all our readers a very Merry Christmas, or at least as merry a Christmas as is possible under our current rather tiresome restrictions. These restrictions, though, are being lifted for a few days over Christmas so that we are able to combine with our families. For many of us, this is something that we Mystery Object have been unable to do for As editor, I would hate to think that you would have nothing to most of the past year. This is occupy your mind while digesting your Christmas pudding so MARTIN a commendable move on the here is our Christmas Mystery Object. The photo is submitted EVANS Editor part of the government and by a reader who recently inherited it. He thinks it appears to be they should be applauded for a tooth setting tool for a hand saw but it doesn’t work on any resisting the temptation to saw he has. The emblem on the lower handle is of a 16 pointed ‘cancel’ Christmas. The last star with a face in the centre, and the marking ‘0.5 – 2.5 mm’ man to do that didn’t make does not seem to relate to the other marking, which is ‘5’. On himself very popular – there’s the inside of the upper handle the number ‘002’ is cast in. a good reason no-one else Is it indeed a tooth setting tool or does it have some other DIANE has tried that during the purpose? CARNEY Assistant intervening 350 years. Editor I think it’s fair to say that no-one could have predicted, is known and we have several believe writing for the magazine last Christmas, what we were promising vaccines becoming provided him with a great deal to experience through the available. More effective ways of personal satisfaction and course of this year. It is almost of treating victims of the sense of achievement. He certainly, within the memory virus have been discovered was also a notably resourceful YVETTE of most of us, the most and more of them are now engineer. We, and his shed, GREEN Designer serious upheaval that we have surviving. All this has been shall miss him. witnessed in our lives. The possible through the enormous nearest comparable event, I advances that have been suppose, would be the Spanish made in medical science over Cock-up Corner ‘fl u pandemic of 1919, just a the last century. In particular, I have to admit that I century ago. The statistics, the great advances made in ‘corrected’ Paul Collyer’s letter however, suggest that our immunology have enabled to Postbag about STEN guns covid-19 pandemic is rather scientists to discover new to state that the ‘ST’ in ‘STEN’ mild compared to that. A and very specifi c ways of represented the designers of century ago, Spanish ‘fl u killed stimulating our immune the gun, Shepherd and Turpin. an estimated 21 million people systems to fi ght the virus. I have been told that this worldwide – more than the I fi rmly believe that 2021 is incorrect and ‘ST’ in fact total number killed by the First will be the year that humanity represents Stirling and Turpin. World War; the comparable will tame covid-19 and other My apologies to Paul Collyer fi gure this year for covid-19 is viruses like it so we can hope for my unwarranted ‘correction’ ‘just’ 1.5 million. to look forward to a very and also of course to Captain We end this year, though, different Christmas next year. David Stirling. in far better shape than we entered it. Last Christmas, according to the evidence James Wells we have so far, the virus was I regret to report the death, already spreading across on the 28th November, of ‘Our Martin Evans can be the globe. At that time, the Man in a Shed’, James Wells. contacted on the mobile virus was largely unknown, in His several articles, and letters number or email below and particular how lethal or virulent to Postbag, were a mine of would be delighted to receive it was likely to be. Doctors information about post-war your contributions, were facing a mysterious social and industrial history in in the form of items of enemy and struggling to fi nd the UK. He also had a rather correspondence, comment or ways of defeating it. At the engaging writing style and articles. end of the year, the virus has I always looked forward to 07710-192953 been unmasked, its genome reading what he produced. I [email protected]
8 Model Engineer 18 December 2020 1
Was this what LBSC saw? A hot air locomotive made by Ernst Plank of Nuremburg. Photograph kindly made available by Alex Prochek (USA). ©Alex Prochek 2020 Hot Air ToyToy LocomotivesLocomotives
odel Engineer is not describing how to make model Perhaps fig 1 represents the usually the place for locomotives. His features locomotive he saw. Roger M toy trains but a long written in a down to earth style He found the answer later. Backhouse ago issue offered a curious were highly popular. Another shopkeeper decorated looks back feature by ‘LBSC’. Lilian ‘Curly’ Sometimes LBSC his window for Christmas with at LBSC’s Lawrence contributed to Model reminisced. In one article a circular tinplate toy railway Engineer from 1924 to 1959. he mentioned a toy hot air track. Goods were displayed reminiscences on A boy from a poor family, locomotive (ref 1). around the track. LBSC noted: toy trains. he learned to make simple He’d often browsed in toy ‘The locomotive was nothing steam engines early, later shops looking at engines he less than a sister to the could not afford. In a shop ‘mystery’ engine which had near London’s Monument he puzzled me! Round it went... saw a distinctive locomotive. but there were no signs of ‘What should have been a any steam... I could see the boiler was merely a blue iron flame of the lamp... apparently casing with a number of licking the end of the long slots... It had a chimney and a tube.’ dome but no safety valve nor What had LBSC seen in the whistle. Through slots in the shops? Nicholas Oddy, editor boiler I could just discern what of Train Collector magazine, looked like a long tube with the suggests the model pictured flywheel at the end. I could also (photo 1). ‘This is a rare thing. just see... a gearwheel inside It was made by Ernst Plank the frame, behind one of the and is different from LBSC’s What LBSC recalled seeing in the toy running wheels.’ The spirit lamp reminiscence. Its boiler was Fig 1 meant it wasn’t clockwork so indeed perforated but oversize shop window at least forty years earlier. he wondered what made it go. because the cylinders are >> www.model-engineer.co.uk 9 comparatively large (being hot rods coming out of each and air). The locomotive towers having a short connecting rod 2 over and is far wider than its made of bent strip, working tender and stock (photo 2). on two cranks at right angles It is very interesting to see it on a crankshaft, made of bent described from memory at rod with a heavy lead flywheel some 40 plus years’ distance.’ in the middle. I recognised See ref 2. Alex Prochek (USA) them as real cylinders, with supplied pictures and also cup pistons having short removed the ‘boiler’ to show connecting rods jointed to pins workings. passing through the pistons Ernst Plank was a themselves, like those on a Nuremberg toy maker. The gas engine. The latter ran firm started in 1866 and was into bearings attached to the one of the first to make toy engine frame and had a small steam engines, also producing pinion wheel near one end, magic lanterns. In 1882 they which engaged with the larger produced Germany’s first toy gearwheel I had noted on the electric train. The ‘Vulkan’ engine in the city shop window.’ The engine is far larger than the tender and rolling stock. ©Alex Prochek 2020 name on the locomotive was LBSC could not see how it also used on other products. worked and noted that on the and this is shown in a video ‘The upper end of the long Difficult times in the 1920’s circular track it did not seem clip (ref 3). cylinder had a leaden cover led to a sale in 1934 and so lively. When the boy told cast on, with the boss in the new owners concentrated on him it would not work LBSC Solving the mystery middle through which the optical equipment. wrote ‘I got one of the long LBSC added ‘I saw in the piston rod passed’. When cylinders off but all there was toy shop... a little stationary power decreased he pulled it to LBSC investigates inside was a jolly long piston engine… This looked like half pieces and discovered how the ‘The tradesmen had a boy thing that didn’t even touch the works of the locomotive hot air arrangement worked. about my own age, and... I the sides, so it must have been stood up on end... The ‘... when the piston in sought him out... but how it made a rotten fit!’ instructions said: Oil all the short cylinder was at worked he didn’t know. You LBSC recalled the price moving parts, fill the cup with the bottom of the stroke, just oiled the works, lit the as 30 shillings. A better cold water, light the lamp and the long piston [displacer] lamp, gave it a push and it constructed model could have give the flywheel a start by was travelling upwards and went! The man in the shop been expected for that money hand. If the water in the cup forcing the air down towards where they bought it called it but track and rolling stock boils and the engine stops, refill the hot end of the cylinder, a hot air engine. He promised increased the price. Maybe with cold water.’ ... when it expanded under to let me see the works... and poor construction explains LBSC had earned money the heat, it travelled through after Christmas this promise why few survived. The gauge from odd jobs to buy the the connecting passage and was fulfilled. was 2½ inches which German engine. It worked as per pressed on the piston in the ‘The iron casing lifted clean makers Bing and Carette called instructions but he waited side cylinder, causing the crank off... What I had taken to be a Gauge 3. For some reason before dismantling the engine to turn (fig 2). long tube, were two very long Ernst Plank called it Gauge 8! as ‘it was put together in such ‘Then when the latter piston things like cylinders, side-by- At least one was built or a way that once dismantled, it was at the top of the stroke the side, close together with piston adapted with a street car body was finished. displacer piston was travelling down, and forcing the air to the cool end where it would Fig 2 contract and ‘suck’ the power piston down again’. The cause of failure was that on the locomotive and the stationary engine displacer piston rods lacked glands. As they wore, heated air leaked out past the piston rod. Oddly, this sounds more like the Ernst Plank locomotive (photo 3) than what LBSC drew. Did he confuse the two? It seems unlikely. Designing a hot air locomotive LBSC often suggested models ‘for the kiddies’ but probably never made them (ref 4). He proposed a model hot air How LBSC recalled the engine’s layout, with two power and two displacememt cylinders. locomotive based on the toy
10 Model Engineer 18 December 2020 LBSC TOY LOCOS he’d seen, noting designs by materials and methods that are Inside the Ernst Plank 3 Artifi cer (Edgar T. Westbury) in most familiar to them. engine with gamma type Model Engineer. He suggested ‘Evaporative water cooling... layout. Thanks to Alex dimensions (e.g. power may have some advantage Prochek for making this cylinders with ⅝ inch bore and over air cooled. A large water available. ©Alex Prochek 1 inch stroke) and suitable cooled engine will be more 2020 materials, recommending effi cient in a large scale, but in light pistons, a fl ywheel and a toy probably unnecessary. a reversing cluster for gears. ‘I would probably add extra A water cooling jacket would, fi ns to the power cylinders to he thought, work better than improve heat rejection at the cooling fi ns. cold end, but again in this size LBSC’s drawing suggested may not affect performance. an engine with two power and Gearing the crank shaft two displacer cylinders plus directly down on to the axle cooling fi ns yet Ernst Plank’s has been proven effective on engine has only a displacer other locomotives I’ve seen. the connecting rods. He used if any Model Engineer reader and power cylinder with water ‘The video proves that a a brass tube as frame and has made anything like the jacket. Was LBSC’s recollection gamma type engine like this spirit container combined, with toy depicted, an opportunity faulty after fi fty years? Did he would work in this scale, but axles passed through the tube. to recreate a rare item of confl ate the locomotive and not to pull any signifi cant Displacement cylinders were toymaking history! the stationary engine? Or was load. A twin cylinder engine 1 inch diameter and power there a four cylinder version? would give more power than cylinders ⅝ inch. He hoped to Acknowledgements It is unlikely, though possible, the single cylinder streetcar experiment with a 5 inch gauge Thanks to Alex Chapman, Alex that a commercial maker in the video. It would be more locomotive but no further Prochek (USA) and Nicholas would use four cylinders when powerful as a beta type engine reports appear. Oddy for making this article two would work adequately. with coaxial power pistons.’ Roy Key’s Caloric No. 1 possible. ME I asked Alex Chapman, a design for Gauge 1 is better fellow SMEE member who Other hot air locomotives known (photo 5 and ref 7). He designed a hot air locomotive Other hot air locomotives gave more construction details for a University project, for his have been described in Model than H. A. Barnett and plans REFERENCES comments (ref 5). He observed: Engineer. Writing in 1958 H. A. are available. Alex suggests 1. LBSC on a hot-air ‘LBSC was clearly familiar with Barnett described an 0 gauge this locomotive is similar to locomotive, Model Engineer Stirling engines. His sketch engine (photo 4 and ref 6). the LBSC drawing but without Volume 83 no. 2068 accurately shows a feasible He was probably unaware of a fl ywheel. (December 26th 1940) engine. His comments about LBSC’s thinking and avoided Like Barnett’s engine this pp 503-505. making pistons as light as use of a fl ywheel and gears. also used two power cylinders 2. Nicholas Oddy: personal possible are valid, and I’ve seen His engine had two power and displacers, having a communication. references to fabricated pistons cylinders with two displacers substantial displacer block 3. Video clip of original hot similar to those he describes. driving cranks set at 90 with holes for additional air engine with street car ‘The late Roy Darlington, an degrees to compensate for cooling. This was gas powered body www.youtube.com/ enthusiastic hot air engine lack of a fl ywheel. He claimed to give better control than watch?v=ovkIJUXKqVU builder, claimed that one of the great success for this 8 inch spirit fi ring. It avoids use of (kindly made available by most successful combinations long model, saying it ran for gears and a fl ywheel by having Alex Prochek). Another was cast iron pistons in a one and half miles round a connecting rods and levers. video clip is more diffi cult phosphor bronze cylinder, circular track on one fi lling - Evidence suggests small hot to open www.facebook. however his engines used quite an achievement. air locomotives can be built, com/100005710098136/ multiple different materials and As cylinders could not align and probably to something videos/962939077239753 piston types and were no less with the centre line of the like LBSC’s specifi cation. It 4. Brian Hollingsworth, ‘LBSC’ successful, so people could use wheels he used levers linked to would be interesting to know his Life and Locomotives, Croesor Junction Press, 1982. 5. Alex Chapman: personal 4 5 communication. 6. H. A. Barnett. Hot Air Rail Motor in 0 Gauge, Model Engineer Vol. 119 no. 2986 (14th August 1958) p 205. 7. Roy Key, Caloric No 1, Model Engineer Vol. 169 no. 3924 (3rd July 1992) pps 40-41 and no. 3926 (7th August 1992) pps 154-155. (For plans H. A. Barnett claimed his hot air locomotive in 0 Gauge Roy Key’s Caloric No 1 is a well-known design see Sarik Hobbies travelled 1½ miles on one fi lling of spirit. His design did for a hot air locomotive in Gauge 1. www.sarikhobbies.com not use conventional locomotive frames. 01684 311682) www.model-engineer.co.uk 11 A trilogy of engines.
Stewart Hart completes his trilogy of PART 9 stationary Grasshopper engines with a grasshopper haulage engine.
Continued from p.735 HaulHaulageage Engine M.E. 4653, 4 December 2020
‘A’ frame assembly (fig 14) ‘A’ frame or alternative allowing a few mm extra on 87 It’s important for the smooth To keep the theme the same the end for squaring up and action of the grasshopper I made the interlocking ring finishing. Square up using the motion that the frame is square design using ¼ x 1 inch thick mill or a file and set square, put to the beam to allow the two mild steel bar, cut to length a good dollop of marking blue swinging cross arms to move freely. The best way to achieve this with modest kit is to give 88 yourself some wriggle room, in not making the fit of the parts too tight, so that you can make adjustment to the alignment (photo 87). I’ve drawn up two alternative designs, one with interlocking rings and the other with plainer straight sided sides. In terms of difficulty I don’t think there’s much Frame assembled square onto cylinder. difference between the two. Frame marked out and outline lightly centre popped.
12 Model Engineer 18 December 2020 GRASSHOPPER
Ø3 or felt tip onto one face and 3 mark out the hole position and M3 the fi nished shape you want it to be. Mark the lines with light r3 centre pops so that you don’t
lose them (photo 88). Drill one 52.5 49
hole right through both pieces 42 31 and bolt the two parts together r2 then drill and tap the remaining Ø2 functional holes (photo 89). Drill out the decorative holes 15 5
Part 26: A Frame Assembly 2.5 (photo 90) and with a hack 1 off 16 saw cut away the unwanted 26 material (photo 91 ), then bring Part 27: A Frame Mat’l: Mild steel, 2 off to the fi nal shape using a M2 5 range of different fi les photo( 92). So you can assemble the Ø7.14 parts in the same orientation 5 24 Ø12.32 as they were made and get 16 24 PCD 26 a square assembly, mark the Ø11.42 Ø17.72 edge of each frame with a light centre pop mark. Ø16 31 r9.71 r12.99 Part 28: A Frame Base 18.57 The base Mat’l: Mild steel, 1 off Ø3 This is made from the same size bar as the frame. The Part 29: Alternative Geometry For A Frame fi rst job is to square up the 30 cut edges, scribe a mark Ø3 r3 across the diagonals to fi nd the centre and centre pop
6 2 (photo 93). Set the base up in the independent four-jaw 13 chuck using the wobble bar method (photo 94), centre drill, followed by a ½ inch drill, then Part 231: A Frame Brace Fig 14 bore out to 16mm for a loose Mat’l: Mild steel, 1 off fi t on the cylinder cover photo( 95). Use the cover as a jig, and using the scribed diagonal 89 90 lines as a guide, position the base squarely on the cover and clamp it. Spot through to mark the hole positions and drill through 3.2mm (photo 96). Carefully mark out the position of M2 holes on one side only and drill and tap them square (photo 97). Screw one frame side piece in place and, in the same orientation as it was Functional holes drilled with parts clamped together. Rough drill out decorative shape. made with its partner, line up the other side piece and clamp it in place. Spot through as 91 92 many of the holes as the clamp will allow you to get to. Drill and tap the holes, assemble the frame, drill and tap any remaining holes, and with any luck you will end up with a reasonably square assembly. Frame brace This is simply made from a length of mild steel cut from a piece of plate, drilled and bent to fi t. Roughly cut to shape with hacksaw. Bring to fi nal shape with fi les. >> www.model-engineer.co.uk 13 I’m not a great advocate 93 94 for fixing the flywheel to the crank shafts of these small engines with keys or grub screws as these tend to induce a wobble
in the fly wheel which Base marked out. Setting on centre using wobble bar. I find annoying. 95 96
Crank shaft assembly (fig 15) Normally when you set the valve events on an engine you tend to rotate the eccentric on the crank shaft but with this slip eccentric design the position of the eccentric is Boring out base to size. Spotting through cylinder cover to mark hole positions. fixed by the drive pin. Instead you have to rotate the crank web, so it is fixed to the 97 98 crank shaft with an M3 grub screw. It’s important that the eccentric drive pin is in the centre of the crank shaft. The easiest way to do this is to make yourself a drill bush from the same material that you make the shaft from - the parts are straight forward enough to make and should pose no problems. Tapping hole square using tapping stand Shaft is knurled for a better grip. I’m not a great advocate for fixing the flywheel to the crank 8 Assemble crank pin with high strength shafts of these small engines Loctite & soft steel pin r6 Ø6 with keys or grub screws as these tend to induce a wobble M3 grub screw in the fly wheel which I find 13.5 annoying. On the horizontal engine I resorted to simply Ø6 bolting the fly wheel up M3 against a shoulder turned on 12 the end of the crank shaft. For Part 43: Crankshaft Assembly Part 45: Crank Web the vertical engine I just used 1 off Mat’l: Mild steel, 1 off good old high strength Loctite – but with this engine having a relatively thin flywheel the contact area for the adhesive was insufficient to create a 114 20 strong bond. I had to give it 8 M3 Ø6 a little extra help by putting a straight knurl on the shaft (photo 98) to give it an extra Part 46: Crank Pin bite in the fly wheel. This, 40 Mat’l: Silver steel, 1 off combined with the Loctite, Part 44: Crankshaft secured the flywheel nice and Mat’l: Mild steel, 1 off Fig 15 concentric on the shaft.
14 Model Engineer 18 December 2020 GRASSHOPPER
Bed plate (fi g 16) This is made from a piece of 99 100 ½ inch aluminium jig plate (photos 99 and 100). Offcuts can easily be bought off the internet auction sites at reasonable cost. The cut-outs for the crank can be easily chain drilled and fi led out but don’t jump in with both feet by marking out all the holes and drilling and tapping them without doing a trial assembly Trimming the edge of the bed plate. Milling cutouts in the bed plate. fi rst. Drill and countersink the 4mm hole that will bolt the cylinder down fi rst then locate 101 102 the bearing stand and the vertical beam and check them for position, with the horizontal beam set level, and mark where they go. Check against the drawing and if they are roughly correct go ahead and drill and tap. You should now have all the parts available to assemble the engine for a trial run Trial assembly of parts. Engine under test. (photos 101 and 102). I had a base available left over from the crank by 90 degrees with at the engine from the front, prevent the crank from slipping a previous engine build that I this engine it leads the crank turn the fl y wheel clockwise, and messing the events up. could use as a temporary test by 45 degrees. It takes a little ensuring that the drive pin is Connect it up to the air and bed. Setting the valve events while to get your head round located on the eccentric fl at. with a bit of luck it should run. is somewhat complicated by this at fi rst but once mastered Position the eccentric in the If it doesn’t, and you are sure this engine’s valve linkage and setting the valves is quite fully forward position at the that you have the events set the angle of the eccentric rod straightforward. half past ten position and the correctly, slowly go around to the axis of the crank shaft, You fi rst have to centralize piston valve will be opening the engine, checking and affecting the angle at which the valve travel by observing half the inlet port. Slacken the dealing with any tight spots the eccentric is at top dead its movement through the inlet crank grub screw and rotate or areas that may be fouling. centre compared with the port, making adjustments with it until it is at the nine o-clock From experience I’ve found crank. Whereas with the other the levers. Once you have the position and tighten the grub one of the best things to do is engines the eccentric follows movement centralized, looking screw up good and tight, to to slacken things off and see if the engine runs - if it does, r4 one by one, tighten things up and if it stops you’ve located a Section A-A problem you need to deal with. 6 M3 To put the engine in reverse 70 40 disconnect the eccentric from the valve, reverse the fl y wheel until the drive pins locates on 15 the other side of eccentric fl at, 29 M2.5 reconnect the eccentric to the 40 valve and it should now run the Ø2 Ø4 csk. other way. Once I’ve got the engine 11
25 running reasonably well I like 90 40 to give it a good run in with plenty of oil. To oil the cylinder 35 35 16 I simply squirt some oil down the plastic air pipe. Connect the pipe up and let the air pressure take it into the cylinder. I’ve A A found that once the engine is run in and fi nally completed it 190 needs very little oiling. I’ve run Part 84: Bed Plate Fig 16 engines for four or fi ve hours Mat’l: 1/2” aluminium jig plate, 1 off without additional oiling. ●To be continued. www.model-engineer.co.uk 15 Book ReviewReview
Ceramic Burners for Model Steam Boilers By Alex Weiss
his is a very useful items needs a lot of book, absolutely full of hunting around. Again, Tdetail, photographs and these are shown in drawings. many photographs. It is conveniently divided The section on into eight main chapters which burners for different cover a lot of questions and types of boiler provides some easy- to-build contains a wonderful ideas. The main chapters are: encyclopaedia of information, 1 - Materials and tools photographs and 2 - Silver soldering burner drawings. It is well bodies worth studying 3 - Burners for round in detail, so read horizontal fl ues it carefully and 4 - Burners to fi t under boilers slowly. Please note 5 - Burners for Mamod and these chapters Wilesco boilers cover building the 6 - Liquifi ed petroleum gas actual burners. (LPG) All the necessary 7 - Operating the burners details for building 8 - Gas control the assemblies to carry the actual gas jets are in running with a steady blue The introductory section chapter 6, entitled Liquifi ed fl ame was always what I tried contains a lot of background Petroleum Gas (LPG) - this is to achieve. which shows that the author towards the end of the book. The LPG section offers has carried out a lot of research There is a lot of accumulated more useful information about over quite a few years. It also knowledge in these pages, gas tanks and gas canisters. contains a lot of examples of some of which must have been Alex compares the difference burners powering different gathered with many hours of between commercial and types of models and boilers. reading previous books, head home-made gas tanks. All The old adage of ‘a picture scratching and burning the of mine are home-made but is worth a thousand words’ midnight oil. Alex has included very wisely Alex suggests the is certainly true in this book. various wonderful photographs best course nowadays is to It is all very well illustrated of the different burners. Some buy a commercial gas tank with copious numbers of show the burner assembly and of a suitable size to suit your photographs. I must admit some show the actual fl ames model. Building the tanks is a that his workshop is better burning on top of the piece of straightforward construction than mine and both workshops ceramic. These cover a range job but, as Alex points out, shown are UNBELIEVABLY of fl ames which are burning getting the tanks offi cially clean. The author’s idea of correctly and also show some tested to 400 psi is not always using honeycomb ceramic fl ames burning with a horrible the easiest task. It is not just which is sourced from the yellow colour. Although most a fi ve minute job sitting in jewellery trade is a new one for of the burner types are much your own ‘shed’. This section me, especially useful if it resists larger than anything I have also lists information about crumbling. Thank you, Alex and ever built, the inclusion of the actual jet carriers and jet Kevin. Many years ago, my very these photographs gives me details. early burners crumbled to dust a lot of confi dence that they The gas control section at the tiniest splash of water. work extremely well. I would covers several types of The materials and tools go ahead and build them automatic control for the gas section, again, offers lots of without any worries. There is supply and the boiler pressure. Published by The Crowood text and photographs with an old saying about the ‘proof In conclusion, this is an Press (www.crowood.com), good ideas on their use. This of the pudding’. This range extremely useful book - go and ISBN 978-178500765-1 also shows some of the heat- of photographs, as a visual buy a copy as a Christmas £16.99. 246 x 189 mm, proof commercial products guide, solves a lot of potential present! 112pp full colour throughout, such as paint or fi re cement - problems concerned with paperback. sometimes trying to fi nd these building and testing. A burner Martin Ranson
16 Model Engineer 18 December 2020 WWormorm and Wheel Gearing in ClockwClockworkork Mechanisms
worm and a mating wheel find many 1 John Aapplications in Moorhouse engineering. In horology we looks at find it in two forms because worm gears, it provides a very convenient form of gearing when we need commonly a large step change in ratio used in clocks and in a single and compact step. automata. Where the wheel is driven by the worm there is a large step down in the ratio, such as for driving slow moving moon dials. Conversely where the wheel drives the worm there is a step up in ratio to drive a fast-rotating fly which is found in musical clocks, pin- lever alarm clocks and also in various items of mechanical music such as musical boxes and mechanical singing birds (ref 1). For a worm driving a slow- moving dial the worm needs to be robust (photo 1), whereas for a step up in ratio they are small and slender (photos 2 to 5). Robust worms can be cut using normal screw cutting techniques whereas with slender worms, generally termed ‘endless screws’, alternative methods may be required. Two start worm driving a slow-moving pinned barrel in a musical longcase clock.
2 3 4
Worm wheel driving an endless in a Worm wheel driving a 1.7 mm diameter single start endless Worm wheel driving a two start endless nightingale musical box (to teach your in a small cylinder musical box. in a pin lever musical alarm clock. caged bird to sing). >> www.model-engineer.co.uk 17
5 6
Worm wheel driving a single start endless in a bird-in-cage movement. Thread milling completed of unsupported blank, with cutter set at helix angle.
Table 1. Key measurements of the endless. the maximum helix angle for the chosen pitch. A double Type Diameter Pitch Starts Helix angle Wheel to worm start ‘endless’ gives the (or lead) step-up ratio benefit of a larger helix angle and therefore easier running Bird box - tabatière 1.5-2.0mm 0.7-1.0mm 1 25 degrees 20 to 1 and starting, with a faster running drive wheel, but a Musical snuff box 1.7mm 0.8mm 1 25 degrees 16 to 1 halving of the step-up ratio. The endless rotates quickly Bird in cage 3.7mm 1.20mm 1 18 degrees 40 to 1 and a fly is mounted on the arbour to act as a speed Pin-lever alarm clock 3.5 mm 4.16 mm 2 31 degrees 9 to 1 governor (rotating in a singing bird mechanism at about 1000 Nightingale box 2.8mm 1.5mm 1 15 degrees 26 to 1 times for each rotation of the spring barrel) to provide a smooth running of the train These slender endless the slightly oversize blank described in ref 2. This and mechanism. screws can be machined can be milled from solid, includes techniques for blank Typical values of the key from hard materials using from the free end, without holding, machining, heat measurements of the endless form grinding with a carefully tailstock support, working treatment and polishing to are given in table 1. dressed grinding wheel. slowly towards the chuck. This ensure an accurate screw with (There are other types of Alternatively, they are reliably approach is termed peeling. true pivots. fast running governors, most cut by thread milling (photo True but oversize pivots are To allow the wheel to of which horologists will be 6) - using the lathe set up best machined at the same efficiently drive the worm familiar with – ratchet wheel for screw cutting but using setting, suitable for holding for the helix angle of the thread and open pallets in alarm a rotating cutter as the tool. finishing and polishing. is necessarily large. For this mechanisms and some small Special cutters in a range of Further details of making reason they are small in walking automata toys; sizes can be purchased and small endless screws are diameter because this gives shutter speed devices in
Table 2. Key measurements of the drive wheels. Identification Bruguier Greisbaum Bontems Flajoulet Griesbaum Nightingale Musical alarm bird box bird box (type 1) bird box double bird box bird box box Endless OD (mm) 1.37 1.97 1.89 0.7 2.8 3.52 Two start Endless thread pitch (mm) 0.75 1.0 1.0 0.9 1.5 4.16 Drive wheel diameter (mm) 5.34 7.01 8.7 4.78 13.3 12.95 (20 teeth) (22 teeth) (25 teeth) (20 teeth) (26 teeth) (18 teeth) Actual drive wheel tip 0.84 1.0 1.09 0.75 1.61 2.26 spacing (mm of arc) Tip spacing / endless pitch 1.12 1.0 1.09 1.07 1.07 0.96 (P/p) (1/2 pitch) Wheel to worm ratio 20/1 22/1 25/1 20/1 26/1 18/1
18 Model Engineer 18 December 2020 WORM GEARS
cameras; centrifugal wheel Table 3. Data from small musical boxes. in a drum in some small bird Bakelite HLMG 544 Spilt comb boxes. On some of these, Identifi cation / marking box movement including the latter, the fl y has expanding blades or arms Number of drive wheel teeth 16 16 16 16 to provide better control and Drive wheel OD (mm) 5.62 4.93 4.83 5.1 to avoid excessive speeds. Endless thread pitch (mm) 0.9 0.8 0.8 missing An alternative method of speed control, used in some Endless OD (mm) 1.68 1.5 1.5 missing bird boxes as a slow closing Endless length (mm) 11.5 missing method to prevent damage to Calculated tooth tip pitch (mm of arc) 1.10 0.97 0.95 1.0 enamel lids, and some French repeating watches to control Tooth tip pitch/endless pitch (P/p) 1.22 1.21 1.19 the rate of the gong striking, is to provide some means of P/p needs to be. In the case It is noteworthy, as is shown to be provided to support the altering the depthing of the of pointed teeth they may in photos 2, 3, 4 and 5, that rounded and polished end of fi nal pair of gears.) engage at their tip or on the the wheel teeth are set not to the pivot. The correct design and side of their tips. A ratio of centrally engage the endless Cycloidal and involute teeth machining of the mating drive less than one leads to two but to engage off from its can be cut by conventional wheel for these endless screws teeth in contact and a high centre line, about halfway means and to create pointed is a vital part in ensuring risk of binding. A value a little to the edge. This has the teeth. I have found the best correct action. Information greater than one means that advantage of reducing the risk method is fl y-cut the wheel obtained from measurements only one tooth is in contact at of the oncoming tooth binding; teeth and then turn away the on both endless screws and any one time and also gives the drive is also at a slightly edge of the wheel equally on their drive wheels in singing an allowance for future wear. greater distance from the axis both sides to thin the tooth bird automata, a musical alarm Involute or other tooth types and is thereby assisting the tips (photo 8). and from four small cylinder will engage differently and not rotation. Correct depthing Thanks to John Farmer musical box movements, is as at the tip and the P/p ratio will of the drive wheel and worm and Tony Allen for helpful shown in table 2. therefore be larger. is important for smooth comments on this article. Data from small musical box Note that for the musical operation and therefore some movements are given in table alarm it has become less than means of providing adjustment ME 3. All of these measurements one, probably due to wear in a to fi nd the optimum setting is have been made on well used device used regularly and not desirable. mechanisms so there may be just occasionally ‘on demand’. An alternative form of drive some element of wear on the In normal gearing the design wheel is found in one type of REFERENCES drive wheel teeth, particularly of involute and cycloidal bird box. This is in nylon with 1. The Endless, K. Fritz, Vol. 7 wheels with fi ne tooth tips. gear teeth is to ensure rolling helical teeth (photo 7). Wear No. 1 pp33-36 spring 1975, It is clear from photos contact, hence there is low will be concentrated in one The Music Box (Journal of 2 to 5 that different types friction and no lubrication is part of the wheel but it can be the Music Box Society of of mechanism have been needed or desirable. However, moved along to another part if Great Britain). See also, designed and operated for a wheel driving an endless required. ‘The Governor’ Vol. 7 No. 2 successfully with different there is continuous sliding Because the endless is pp68-70. types of drive wheel teeth. friction and therefore a highly driven axially by the tooth it 2. Machining Endless Screws, Clearly the type of drive wheel polished and true endless creates an end thrust which Horological Journal, Vol. teeth and their actual point of is vital. Lubrication is also has to be catered for. A hard 2 2010 pp63-6 and Music contact with the endless will essential and a watch pivot oil polished steel plate or, for the Box Magazine 2011 Vol. 25 determine what the value of serves well. picky, a fl at ruby jewel, needs pp57-60). 7 8
Nylon drive wheel in Griesbaum bird box. Fly cut drive wheels prior to thinning of the pointed teeth. www.model-engineer.co.uk 19 CCavalryavalry SwordSword
Our Man in a Shed, James Wells, recalls a foray into the world of the armourer.
hile on military service grooves in the blade, I asked Much to my relief the first WI was tasked by the one of the more experienced attempt shaped up reasonably Officers’ Mess to machinists to mill the grooves well and no repeats were make a miniature cavalry in the flat blade strip. Nobody necessary. sword as a presentation gift seemed to know the correct With the hilt attached to the for a retiring brigadier - an name for these grooves, blade, shaped Tufnol strips interesting challenge! although ‘fullers’ was popular used for the handgrip, a final The starting point was but other suggestions ranged polish up followed by attaching the Armoury loaning me a from ‘gutters’ to ‘runnels’. The to a varnished wooden backing Wilkinson´s 1908 cavalry blade material was then ground shield, the presentation gift was sword for measuring and and filed down to the final intended to be completed ready sizing up the miniature sword. shape using hand tools and for the ceremonial dinner. At The first lesson was that an removing the milling machine this stage the whole plan went exact half sized copy looked marks from the grooves. wrong. The whisper reached me rather disproportionate so The basket work was a that the brigadier’s wife didn´t the blade became slightly more interesting challenge. want weapons in the house, so shorter than exact half size. The various piercings and an engraved silver tray had to At the same time, I took a engraving were marked onto a be hurriedly purchased. tracing of the basket work hilt flat piece of brass then drilled There was an interesting and then reduced this on a though where necessary, lines comment by the adjutant photocopying machine. gently engraved with small though. It seems that after long Medium and high carbon chisels and the various wavy debates in cavalry circles about steel seem to have a better grooves connected up with an the relative merits of the lance surface finish after filing than Abrafile. It all rather reminded versus the long cavalry sword the more usual grades of me of schoolboy days with for mass cavalry charges, the mild steel so I decided to use fretwork. All rough areas in the whole matter had finally been medium carbon steel for the grooves were then carefully finally decided in favour of the blade. This was in stock as cleaned up with needle files long sword. Unfortunately it round bars so a suitable piece and the outline made while still was 200 years too late. was forged down from a round a flat plate. For the military buffs bar to a flat strip. After carefully annealing out there, were any left- At this stage I have to admit the brass plate this was then handed cavalry swords ever to cheating - after annealing shaped by gently hammering manufactured? the strip, rather than forge the down on the usual sandbag. ME
20 Model Engineer 18 December 2020 www.model-engineer.co.uk/classifi eds/ FREE PRIVATE ADVERTS
Machines and Tools Off ered Models ■ Air compressor Jumbo. Little used, ■ 5” gauge G.W. pannier locomotive Did You Know? You can now place your plus air lines, tyre gauge and line guns. with fully detailed coach. Bronze classifi ed ads by email. Just send the text All in good condition. medals for each. £7,500. of your ad, maximum 35 words, to neil. T. 01708 720355. Romford. T. 01776 700611. Stranraer. [email protected], together with your full name and address, a landline ■ Coronet Imp bandsaw, 12” throat. 3 ■ Brahminy - a 2.5” by 2.5” single telephone number, whether it’s a for sale speed for wood or metal. £125 ONO. cylinder steam engine suitable to or wanted and stating that you accept the Denham Junior 4 ½” lathe geared head power up to an 18 ft . long steam terms and conditions for placing classifi ed lathe 12” swing in gap, 3 jaw, 4 jaw, T/ launch on lakes or canals. See ME ads – see below. Please note, we do not stock shucks, face plate, catch plate, 4454 to 4464. £900. (Pumps can be publish full addresses to protect your fi xed and travelling steadies. T.D. ind. added at extra cost). T. 01702 231129. security. Full set change wheels for Imperial and Rayleigh, Essex. metric. Mounted on adjustable feet. £650. American Paterson 4 ½” v-bed ■ Model locomotive for sale. £3, lathe. 3 jaw, 4 jaw, tailstock chucks. 700 plus post and package. It is Magazines, Books and Plans 3 face plates. Fixed steady. Full set packed into boxes. One box is has the ■ Model Engineer bound copies change wheels. 4 way tool post. Power locomotive in it minus the boiler. The nineteen 1948 and up to 1963. Not cross feed, £300. Clarke MIG welder 15/ other box has the tender , which is continuous years. Sensible off ers TE Turbo fan cooled £150 ONO. fully operational, and the other item please. Collection only subject to Covid T. 0161 330 5112. Manchester has the boiler which needs the full test restrictions. T. 07876 565755. York. certifi cate. Unfortunately the boiler ■ Wooden cope and drag, unused has a leak inside the fi re grate and is Wanted 8 ½” square. 6” deep. £15. 2 Bunsen leaking down the down tube. ■ Wanted Rob Roy steam locomotive burners. 2 large blowlamps, 1 smaller T. 0033 549 84 32 26. and drawings. A tired example might blowlamp. Mains gas and air. Unused Brigueil Le Chantre, Vienn, France. be OK, tested would be better. £40. T. 01409 211102. T. 01905 345537. Droitwich. Beaworthy, Devon. Parts and Materials ■ Do you have a copy of Model ■ Anvil and mobile forge. £55. ■ Maid of Kent. 15 diff erent castings. Engineer issue 4646 (28th August)? If T. 01277 372011. Brentwood. £200 ONO. Inside cylinder, complete so I would pay £5 for it, plus postage. rolling chassis. £1,800 ONO. T. 07710 192953. Cambridge. ■ Proxxon tools boxed, unused. KT150, T. 07720 835320. Crewkern, Yeovil. FKS/LE, ES220/E, FT300, NG5/E, ■ Wanted: ‘Locomotives and Large KB220, BFW34/E, MINIMOT 4, KG220, ■ 67 feet 3 1/2” – 5” – 7 ¼” welded and Small’ magazines by Don Young, OF3, 4 cutters, MBS140, BSL220/E, steel track. £150. T. 01776 700611. Issue 17, Nov.1983 plus Issue 20, Aug. WSL 220/1, BFO2000. Sell one lot, Stranraer. 1984. T.01926 624858. Warwick. £600. Free delivery. T. 01340 810687. Aberlour. ■ Large quantity of stationary engine castings. Two Stuart No. 9, one Score. ■ Emco Unimat 3 milling machine Many other beds, cylinders, cranks, Rejon high torque motor. Conversion fl ywheels. Complete Stuart reversing vice collets collet chuck Jacobs chuck gear. All must go. One lot. Collect SE fi ne feed attachment saw arbor milling London. T. 0207 274 9211. cutters tilting head £560 free delivery Herne Hill, London. uk mainland. T. 01474812148. Gravesend. ■ Part built 3 ½” gauge Rob Roy 0-6- 0 chassis, approx.. 80% comp[lete on building stand. Chimney, dome, smoke Classifi eds and Coronavirus box door and ring, Boiler part built in Please follow local government advice copper. Firebox and tube assembly, in Wales, Ireland, Scotland or England as tube plate and backhead fl anged. appropriate if you are considering buying T. 01442 266050. or selling items for collection. Please Hemel Hempstead. respect the needs of delivery drivers to protect their own safety and, if receiving ■ Full set of castings for 2 x Foden a parcel take sensible precautions when steam wagons (“C”type and “J” type) handling anything packaged by someone designed by Terry Morris. The J type is else. built up with boiler. Open to off ers. T 07768 643485. Haydock. A Not PParticularlyarticularly Silent Night
h, for goodness sake! Can't you Rafe ''Ofind something to Shirley’s do in your workshop?'' This deep and request came from a slightly dreamless exasperated wife and, indeed, sleep is I think that she had every right to be so. It was Christmas rudely disturbed. Eve and in spite of the sleet I had done the jobs of draping lengths of the appropriate festive lights round the tree in the front garden, tested same to make sure they were all working or, at least, most of them, moved furniture around to accommodate Christmas Day visitors and obtained the vital supply of draught beer and other liquid consumables to lubricate the coming occasion. My wife is a very organised person and was moving rapidly amongst bubbling saucepans, various mounds of ingredients war dance and using a few The noise, when it came, had of one sort or another and expressions picked up during me instantly awake although was in no mood to tolerate a short spell in the haulage my wife seemed immune a husband hovering about in industry, I realised, with some and continued to emit a long search of a stray mince pie. relief, that the tap had not stream of 'Z's. It started with So off I went down the broken off flush with the block a slight thump followed by a garden and in twenty minutes but that there was a length sort of slithery sliding sound. Christmas had been forgotten. sticking up out of the hole. ''Oh no,'' I thought, ''have we The job in hand was a cylinder Accordingly, by using gentle lost a tile?'' I glanced at my block for an 'O' gauge live heat, light oil, a fine pair of watch, eight minutes past steam locomotive. The bores pliers and lots of care the end two, ungodly hour, however had been drilled, reamed of the tap came loose and better go and have a look or and lapped to a high finish, with a final slight resistance, I shan't sleep another wink. the steam chest and covers emerged from the hole. So, it was on with the top coat completed and the holes for So far so good. However, it and boots, find a torch and out the bolts drilled. The only job was my only 12BA tap so that on the back yard where, just left was to tap the holes 12BA - would seem to put the kibosh to cheer matters up, the sleet quite a small thread - and then on the job until the New Year. had turned to snow. A quick the exciting business of trial Indeed, it was a thoughtful look on the ground revealed assembly could begin. figure that wended its way no broken tiles so I turned the Three more holes remained down the garden path to its torch beam on the roof. Up and I was on the first of them evening meal and the usual between the dormer and the when 'ping!', one of the worst rendezvous with the telly. With chimney there seemed to be sounds in model engineering, the respective endeavours of quite a large and long object. that of a 12BA tap breaking the day behind us we both felt There were signs of movement off in a cylinder block. like an early night so 10 o'clock at the rear so I shouted up, ''Oi! After doing the necessary saw us in bed and asleep. Get off our roof!''
22 Model Engineer 18 December 2020 XMAS TALE
Into the torch beam came a little old chap in spectacles and some sort of fur hat. ''What's going on?'', I asked. ''Look,'' he said, ''sorry about the disturbance but you've got one of the few chimneys left in the village and I like to get the easy jobs out of the way fi rst. What with all this central heating about these days I have to use the letter boxes and it's a devil of a squeeze, especially at my age.''Hello, I thought, we appear to have a right one here. ''I also have another problem,'' he continued, “one of the runners on the sleigh has come loose and we could be in trouble if it comes off altogether''. Well, naturally, I suspected some form of practical joke but thought that I would play along. ''Well, I can't do much about the letter boxes'', I said, ''but if you can get the outfi t down on to the back lawn, whilst I fetch a few tools, we'll take a look at the runner''. By the time I had found a couple of screwdrivers and the mole grips the sledge was at ground level and I had a quick glance at the motive power which I noticed that the old gent the other side which seemed Having put the car jack and seemed to be some sort of was stamping his feet and fi rm enough. I said to the old the rest of the kit away, I locked draught animals but couldn't shivering a bit and that the chap that corrosion had caused up the garage and house, really tell as they were partly animals seemed to be doing the runner to work loose and dropped the envelope on the concealed by the dark and the same. I asked him if he that brass screws should really table and wended my way up to various shrubs. I thought was all right and he said that have been used from square the land of nod where I noticed to myself that if this was a what with doing nothing for a one. He said that the problem that my wife was, thankfully, practical joke no expense while, the cold was starting to might have been aggravated still in residence. Before appeared to have been spared. strike through his boots. by the sleigh only being used dropping off, I looked again at The brass sled runner ''Would you like a drink?'', I once a year and that he would my watch and noted that the had partly pulled over the asked. ''Well, I normally get the have a sharp word with the time was still eight minutes countersunk screws holding odd glass of sherry'', he replied. maintenance staff when he got past two although the watch it on. These were of steel and ''Sherry won't do you any good back up north. seemed to be working perfectly. had badly corroded. I tried on a night like this'', I said, “I'll He then climbed back into ''Odd'', I thought as the mists of to lift up the sledge but - my go and fetch something to the driving seat and picked sleep took over. word - was it heavy for its keep out the cold''. Back I went up the reins. ''Thank you for Christmas morning came size. I nipped back into the into the house and into the your help tonight'', he said. soon enough and we were up garage and got the car jack pantry. A generous measure of We shook hands and I noticed early to start preparations for and a piece of plank. With rum was poured into a tumbler what a fi rm grip he had for the visitors. Whilst bolting the old scissors jack on the and at the same time I picked an old bloke and that his down my fruit and bran I job, the sledge or sleigh or up half a dozen carrots from eyes seemed to twinkle quite caught sight of the envelope whatever it was soon at an the vegetable rack. brightly behind his glasses. He lying on the table. I opened it angle where I could get at the Back on the lawn, I gave the reached into his side pocket and out fell three 12 BA taps, runner. A couple of quick jerks rum to the old gent saying, and produced an envelope, taper, second and plug. All and it was off. The mole grips ''This is medicine, down in ''Here's a little something for high- speed steel too. made short work of removing one please and if you feel like your trouble. Anyway, I must Just then my wife came out the stubs of the screws and, handing out these carrots to be off as there is some time of the pantry. ''I could have after all, I had the afternoon's the troops I'll get on with the to be made up''. I bent down sworn that I had more carrots experience to draw on. A quick job''. The cold was starting to pick up the tools and when than that'', she said, ''and have search of the garage produced to get to me as well. Anyway, I looked up the whole lot had you been at the rum?'' ''Yes half a dozen suitable brass the runner was soon screwed gone but there was a sort of dear'', I replied, ''I suppose that replacements and I was about back in place and the jack frosty mist hanging in the air I must have been''. to start putting them in when removed. I had a quick look at where it had been. ME www.model-engineer.co.uk 23 The Barclay WellWell TTanksanks ooff the Great WWararPART 69
This constructional series addresses Andrew Barclay 0-4-0 and 0-6-0 narrow gauge locomotives supplied for use in the First World War. Built without the use of castings, the Terence 0-4-0 design is described as two versions; as-built for the British Admiralty in 1918 and Holland as rebuilt and currently running on the Talyllyn Railway as their locomotive No.6, Douglas. describes The 0-6-0 engines described were built in 1917 and operated on 60 centimetre gauge and track at the Western Front in France. These were small, spartan machines of which only 25 constructs were supplied and none have survived into preservation. two appealing, century old locomotives. The well tank 1 Once the frame assembly is be made from ⁄8 or 3mm mild 1 - four holes for the cart completed the tank needs to steel plate. Compared with spring push rods; Continued from p.691 be sealed in some way. The the 0-4-0 the lid is narrower, 2 - the cutout for the M.E. 4652, 20 November 2020 details of the tank top are as there are no external top axlebox oil-box; presented in fig 223. Note that, angles attached to the frame. 3 - a hole at the front as there is only one tank, the The lid, therefore, screws into for the water filler. vent and balance pipes are the ½ x ½ x ⅛ inch angles not required. As little or no fitted to the inside of the Figure 223 also details the corrosion is likely to take place frame. The cutouts in the lid support plates for the bunkers. under the tank lid, this can are as follows: On my original engine (as mentioned earlier in the series – M.E. 4515, August 2015) 19 1/8 I managed to obtain a twin- 3/16 pack rubber sealant - I seem to 7/8 remember it falling off the back of a lorry... This needed mixing and then swirling around the 4 holes Ø7/32 for completed tank to apply a spring pushrods good, thick coating of sealant, 4 5/8 4 1 5/8 1 rendering the tank completely 2 1/2 2 2 typ. 1 1/4 1 21/32 typ. 21/32
23 holes 21/32 5/8 typ. 5/8 watertight once cured. Ø7/8 Ø2.9mm csk. 1 Unfortunately, I was unaware at the time that leaching of the lining material took 9 1/8 3/8 place in service and this 10 3/8 5 1/2 was surreptitiously causing Well Tank Top 11/32 severe priming. Assuming it Mat’l: 1/8” M.S. 5 3/8 (check on job) was a boiler design problem, I tried extending the inner dome take-off pipe, adding 2 holes Ø2.9mm csk. 2 typ. 1 1/2 1 3/8 baffles to the dome and other r3/8 ideas, but never succeeded
4 5/8 4 in curing the problem. Once 3/4 3/4 3 5/8 3 1 1/2 1
5/16 my tender was complete (the tank of which was sealed in a more conventional manner) 1/2 I stopped taking water from 11 1/4 the well and the problem Bunker Support Plate ceased. So, suspecting the Mat’l: 1/8” M.S. tank lining, I disconnected the LH drawn well tank from the feedwater Fig 223 Well tank top and bunker support plates. system. Later, when rebuilding, I removed the two-pack rubber
24 Model Engineer 18 December 2020 BARCLAY LOCOMOTIVE
lining and sealed the well with several coats of thick, good Fig 224 old-fashioned, red lead paint. Priming problems are no more and the well tank is back in service. This just goes to prove that some of these new-fangled materials are not always what they are cracked up to be - posh job but total disaster! Axlebox oilers As I can’t fi nd any trace of an oil-box for the axles and axleboxes on the original Schematic of axlebox lubrication. drawings and photographs of big brother, I presume that lubrication was carried out by in fi g 223. Details of the oil- periodically poking an oilcan box and water fi ller will be 317 through the wheel spokes. published later. However, it would obviously be an advantage to have some Current progress means of lubrication similar in Norfolk to that on Douglas (see fi g 40, Photographs 317 to 319 M.E. 4525, January 2016). In illustrate current progress fact it’s not a surprise that with Mr Simmons’ engine in the 0-6-0s were not so fi tted, Norfolk. It can’t be all that far as photographs of Barclay off its fi rst steaming but it will engines 1431 and 1432, be a shame to light a fi re on taken at the works, give some that pristine grate! indication that oilboxes were not fi tted to the 0-4-0s when ●To be continued. they left Kilmarnock. To simplify things I have specifi ed a single box with six ⅛ inch diameter pipes that are hard soldered in place. NEXT TIME Make the box as shown in fi g I shall move on to the tank 40 but slightly larger, say 1¼ fi ller, oilbox and drawgear. by ⅜ inch with a depth of ¾ inch, which should provide a reasonable amount of oil as well as space for the pipes to be silver soldered into The Norfolk engine with its new position. The box is screwed boiler (photo: Anthony Simmons). to the rear of the well tank stretcher with a couple of 6BA bolts and the pipes run to the 318 319 six axleboxes – these are held in position with suitable clips if necessary. The rear spring stretcher has 3 two ⁄16 inch diameter holes in it to make running the rear set of pipes a bit easier. Fitting the oil box and running the pipes before the tank lid is fi xed does mean that the lid will have to have a cut-out, which fi tsover the box to enable it and its pipes to be fi tted before the lid is screwed down. See the sketch presented in fi g 224. The cut-out for the oil-box is Grate and ashpan the square opening shown Front view (photo: Anthony Simmons). (photo: Anthony Simmons). www.model-engineer.co.uk 25 Making a Stand 1 That Will MakeMake YourYour Model Steam Engines PProudroud
f you’ve built a couple of locomotives you tend to run Luker shows Iout of space in a small home how you can relatively quickly, especially if display your you don’t have a garage (don’t work to best ask me where my lathe and milling machines are!). With advantage. my next locomotive nearing completion, I had to make a Frame with future locomotives fitted. plan relatively quickly. The domestic COO was also not locomotives you have built. steam day related storage and happy with the large 7¼ inch I had one client that wasn’t the passenger cars. Using the gauge Stirling on the good sold on my rates and services rendering from my designs the carpet in the spare room, so until he saw my locomotives; guess work of how it will look I decided to make a large I closed that deal five minutes can be eliminated and makes display stand in my work study later and have had a number for an interesting picture and move the shop press into of additional contracts from (photo 1). The locomotives that spare room (when the that company. will be transferred to the upper COO wasn’t looking). The requirements for the tiers using a purpose designed I’m also very fortunate to be stand were simple; it needed rope winch lift. able to consult from home and to be able to take a number if you are in the engineering of locomotives; it needed The skeleton frame consulting game no one will to look good and take up All the tracks were made argue the benefits of showing minimal space, which is tricky using 19 x 38 x 1.6mm tubing. potential clients the steam considering the size and The uprights were fashioned weight of my locomotives. from 38 x 1.6mm square My super-dainty, beautiful tubing with the cross bars 32 2 wife and I also needed to be x 2mm square tubing (photo able to move the stand into 2). The 2mm tubing is easier the house without breaking to weld perpendicular to the our backs so weight was a uprights and a good weld is consideration. And, as with all critical with the crossbars. my designs, minimal materials All welding was done using and absolute minimal wastage standard inverter arc welding, is a necessity. I trust this over MIG, and you With the above in mind I can clearly see if you haven’t decided to build a four tier welded a corner properly. stand 2m long, 480mm wide The tracks serve as and roughly 2.2m high. The structural members and top tier will take the smaller because the frame is not locomotives including my 3½ boxed at the corners a small inch gauge 2-6-2T and the 5 amount of flexibility is possible inch gauge 0-4-0 Ballaarat to take up any irregularities in I’ve just finished designing. the floor. The uprights have The third tier will take my 5 two bolt holes, two thirds up, inch gauge American type for M8 Rawl bolts as a safety locomotive Wahya and the factor when loading and second tier my large 7¼ inch offloading the top locomotives. 2-2-2 Stirling Single. The The ends of the tracks Bottom frame with four tiers. bottom tier will be reserved for were cut out to line up with
26 Model Engineer 18 December 2020 LOCO STAND
3 4
Assembled frame. Wood fi tted to frame and treated. the bottom of the cross bars it needed to be smooth and and has no structural function water based acrylic (dark which extended them over the easy to move the locomotive but is necessary to close up mahogany). I have found crossbars to allow smooth onto the stand. the back of the stand nicely. this gives some measure of transition when loading (photo I had to make the top section Pre-drilled angles were protection against water and 3). I didn’t want to use force separate to get the stand welded to convenient positions oil from the locomotives. when loading a locomotive through the door; this part just for fastening the wood. The At this point the stand was onto the stand above my head; slips onto the bottom frame wood itself was not designed carried into the study, for fi nal to be load carrying and is just fi tment of the lights, bottom 5 for aesthetics. door and drip trays. You can see from the picture (photo Adding the wood 5) the large locomotive fi ts as After painting the frame I snug as a bug and at no point could add the wood (photo 4). is lifted or lowered. The transfer Some of the wood came from cart is at the same level as discarded packing crates and, the back of my bakkie and the to be honest, this wood was stand. (‘Bakkie’ is the South better quality than the wood African word for a small truck - I had to buy to fi nish the job. basically the front is a car and Pine was used throughout the back is a small truck.) The and it was stained with a trains are locked in place on the 6
Bottom storage for steam days. Locomotive lift in action. >> www.model-engineer.co.uk 27 7 8
Frame lift top. 9
Frame lift bottom. stand using the tender breaks, imagine the tears if one of my and during transport rigid hold locomotives came crashing downs are used. down. I have no intention I used 220V LED lighting of building another large strips fitted to the front- locomotive like the Stirling and top of each level and some if I did it would not be lifted; strategically directed 12V LED it’s just not worth the risk. With lights (the transformer came that said the lift was designed from an old aerial system) to to take around 60kg safely show off the backheads. The (photos 7, 8 and 9). wood behind the locomotives The same tubing was used serves as a convenient for the lifting frame with the mounting for the odd casting lift itself taking advantage pattern and locomotive of the 38mm slipping neatly memorabilia which gives an over the 32mm tubing. The interesting indication of scale. sliding part of the lift was The bottom door was made constructed at a 45 degree using 6mm pine plywood and angle; this with the weight roof trestles with the slots of the locomotive ensures for the pine board cut using a the sliding face(s) reacts Frame lift. cheap table saw I bought for on a corner and not a flat. I the model locomotive footplate did this to prevent the lifting There is also a gusset welded value is useless because boards. Each tier has provision platform from tilting which to the upright to increase the I’m not sure when next our for sliding clear polycarbonate could result in catastrophe. strength of the bottom frame politicians will be giving a panels but I’ve decided not With this configuration there is and decrease the reliance on speech. So, instead, I’ll give to fit these, simply because I minimal sideways movement the welding. the universally accepted use the locomotives relatively (parallel with the floor) but hamburger and cool drink frequently so a little dust on with the casters locked up Cost of everything equivalent; of 37 meals (290 them won’t bug me too much. against the stand this is not an For interest I kept close track US$). Sadly 50% of that was issue. A standard hand gear of all the costs including the wood I had to buy to finish The locomotive lift winch lifts the locomotives the gear winch, steel, the the project. I guess for Timber The locomotive lift (photo 6) with ease but the rope needs screws and rivets used for City money really does grow is by far the most critical of to be tightly reeled to prevent fitting the backing boards etc. on trees! the entire system. I could only it from slipping under load. Unfortunately giving a Rand ME
28 Model Engineer 18 December 2020 Incorporating Mechanics, English Mechanics and Ships & Ship Models
TO VOLUME 225 INDEX June to December 2020 EDITORIAL PAGES INDEX INDEX 19th June 2020 – 2nd July 2020 4641 8-52 Index to volume 224 4641 29 3rd July 2020 - 16th July 2020 4642 68-112 17th July 2020 - 30th July 2020 4643 128-172 MAIN AUTHOR INDEX 31 July 2020 - 13th August 2020 4644 188-232 Arrowsmith John We Visit - 512 14th August 2020 - 27th August 2020 4645 248-292 Ickenham 28th August 2020 - 10th September 2020 4646 308-352 Arrowsmith John We Visit - Kinver 369 11th September 2020 - 24th September 2020 4647 368-412 Arrowsmith John We Visit - The 78 Cardiff MES 25th September 2020 - 8th October 2020 4648 428-472 Arrowsmith John We Visit - The 201 9th October 2020 – 22nd October 2020 4649 488-532 Hereford SME 23th October 2020 - 5th November 2020 4650 548-592 Arrowsmith John We Visit - The Tree 729 6th November 2020 - 19th November 2020 4651 608-652 Tops Railway Backhouse Roger Engineering’s 193 20th November 2020 - 3rd December 2020 4652 668-712 Local Heroes - 4th December 2020 - 17th December 2020 4653 728-772 ‘Postie’ Lawson Backhouse Roger Engineer’s Day Out 313 - Haarlemmermeer COVER PHOTOGRAPHS Backhouse Roger Engineer’s Day 633, 683 4641 Richard Castle's Bolton Marine triple expansion engine Out - Isle of Man 4642 Neil Wyatt's model of a Chadwick 'A'-frame Engine Railway Backhouse Roger Prostate Cancer 449 4643 Cab view of Wahya, a freelance and Model American 4-4-0 locomotive Engineers 4644 Helmut Heitzinger's model of the Barber Norman Making Hexagonal 456 Musgrave compound engine Sockets Simplifi ed 4645 One of a pair of 7¼ inch gauge 'Jinty's built by Tim Coles Brown Richard Scale Model of 258 a 10 Inch Land 4646 The 'grasshopper' haulage engine built by Stewart Hart Service Mortar 4647 Tim Bradford's 'Sweet Pea' undergoing Carney Diane Park Street Mill 189 its boiler test at Kinver Engine 4648 Keith Foskett's Gold Medal winning Castle Richard Bolton Marine 9, 148 6 inch 'Little Samson' Triple Expansion Steam Engine 4649 John Merrett's 5 inch gauge LB&SCR Coles Tim Model Steam 206, 249 'Terrier' tank locomotive Locomotive Boiler 4650 Hunslet locomotive Velinheli, seen at Cleading the Ffestiniog Railway Couchman Ian Weir Pump 40 4651 Parts for making an experimental fl angeless Cruickshank Frank A ‘Glass’ Case for 326 5 inch gauge boiler your Model 4652 A pair of 'Molly Anns' driven by Daco Half Size Lister ‘D’ 744 Helen Hale and Hilary Smith Stationary Engine 4653 Ian Couchman's Model Engineer beam engine de Ruiter Henk-Jan Slot Cars Again 285 MAIN AUTHOR INDEX MAIN AUTHOR INDEX Dupre Alex Dividing in the 437, 493, Maurel Jacques In Praise of the TDI 34 Lathe 576 Merrett John LB&SCR Terrier 489 Feast Nick Displacement 86, 142 Tank in 5 Inch Lubricator for Gauge Charlie Merrett John Two Little Engines 376 Freeman Jon Petrol Engine and 642, 702, Moorhouse John Confessions of a 81, 211 Alternator Sets 763 Model Maker Gearing Martin Tempering and 73, 159, 196, Norton Norm Britannia Class 7 578, 613, Gear Cutters 252, 405 Locomotive in 5 692, 758 Gunn Chris Garrett 4CD 92, 226, 320, Inch Gauge Tractor 453, 552, Oldfield Rodney Middleton Double 47, 100, 166 673 Sided Beam Engine Hart Stewart Grasshopper 309, 401, Owen Phil Obituary - Jack 336 Haulage Engine 466, 523, Buckler 582, 636, Owen Rhys Railway Brakes 392, 446, 679, 733 504, 563 Hartland David Seventy Year 274 Pâques Joseph- Copper Boilers 609 Search Jean with Flat End Haythornthwaite David Building the Model 18, 137 Plates Engineer Beam Phillips Les Simple But 102 Engine Effective Depth Heitzinger Helmut Musgrave Non 190, 280, Stop Dead-Centre 343, 384, Probyn Andy Showcase 569 Compound Steam 443, 520 Rigby Peter Experimental 618 Engine Tipping Bucket Herbert Dennis Obituary - Trevor 562 Rain Gauge Shortland Ritchie Paul Little Samson 429 Hewson Doug New GWR Pannier 76, 215, 333, Models 459, 559, Robinson Martin Queens Messenger 272, 318, 676 388 High Malcolm Small Locomotive 204 Roger Backhouse Engineer’s Day 15 Boiler Feed Pump Out - Basingstoke’s Hobbs Robert GWR ‘County’ 209, 255, Milestones Locomotive 347, 373, Museum 430, 500, Ron Fitzgerald Stationary Steam 37, 145, 266, 570 Engine 398, 497, Holland Terence Barclay Well Tanks 104, 222, 639, 746 340, 451, Sayers Mike Obituary - Tom 743 586, 687 Pasco Hotspur Wenford 43, 162, 261, Shelley Noel Smoke Signals 151 394, 508, 646, 736 Shirley Rafe Showcase 436 Jennings Jim Adventures with 442 Smith Peter Making of 669, 766 Blowers Hilary Jane Kerr Les Making PCBs at 433 Smithers Mark 150 Years of the 516, 549, Home Quarry Hunslet 621, 706, Dynasty 754 Langer Graham P2 Locomotive 573 Pony Truck Smithers Mark Loco Worth 94, 155 Modelling Langer Graham Prince of Wales 324 Crank Axle Spedding Geoff Murdock Vertical 106, 218 Oscillating Engine Luker Fantastic Materials 13 and Where to Find Tanner Paul Siding Lockout 214 Them Device Luker Making 555 Theasby Geoff Club News 50, 110, 170, Locomotive 230, 290, Name Plates 350, 410, 470, 530, Luker Wahya 24, 90, 129, 590, 650, 286, 380, 710, 770 526, 629, 749 Walker Robert Stress Corrosion 390 Maurel Jacques Drill Press 625, 697 Webster Duncan Rippling Tractive 134 Improvements Effort INDEX
MAIN SUBJECT INDEX MAIN SUBJECT INDEX 150 Years of the Quarry 516, 549, 621, 706, 754 Making PCBs at Home 433 Hunslet Dynasty Middleton Double Sided 47, 100, 166 A ‘Glass’ Case for your Model 326 Beam Engine Adventures with Blowers 442 Model Steam Locomotive 206, 249 Boiler Cleading Barclay Well Tanks 104, 222, 340, 451, 586, 687 Bolton Marine Triple Expansion 9, 148 Murdock Vertical Oscillating 106, 218 Steam Engine Engine ‘Britannia’ Class 7 Locomotive 578, 613, 692, 758 Musgrave Non Dead-Centre 190, 280, 343, 384, 443, 520 in 5 Inch Gauge Compound Steam Engine Building the Model Engineer 18, 137 New GWR Pannier 76, 215, 333, 459, 559, 676 Beam Engine Obituary - Jack Buckler 336 Club News 50, 110, 170, 230, 290, 350, Obituary - Tom Pasco 743 410, 470, 530, 590, 650, 710, 770 Obituary - Trevor Shortland 562 Confessions of a Model Maker 81, 211 P2 Locomotive Pony Truck 573 Copper Boilers with Flat 609 Park Street Mill Engine 189 End Plates Petrol Engine and Alternator Sets 642, 702, 763 Displacement Lubricator 86, 142 Prince of Wales Crank Axle 324 for Charlie Prostate Cancer and Model 449 Dividing in the Lathe 437, 493, 576 Engineers Drill Press Improvements 625, 697 Queens Messenger 272, 318, 388 Engineering’s Local Heroes - 193 ‘Postie’ Lawson Railway Brakes 392, 446, 504, 563 Engineer’s Day Out - Basingstoke’s 15 Realistic Bases for Model Engines 69 Milestones Museum Rippling Tractive Effort 134 Engineer’s Day Out - 313 Scale Model of a 10 Inch Land 258 Haarlemmermeer Service Mortar Engineer’s Day Out - Isle of Man 633, 683 Seventy Year Search 274 Railway Showcase 569, 436 Experimental Tipping 618 Bucket Rain Gauge Siding Lockout Device 214 Fantastic Materials and 13 Simple But Effective Depth Stop 102 Where to Find Them Slot Cars Again 285 Garrett 4CD Tractor 92, 226, 320, 453, 552, 673 Small Locomotive Boiler 204 Grasshopper Haulage Engine 309, 401, 466, 523, 582, 636, Feed Pump 679, 733 Smoke Signals 151 GWR ‘County’ Locomotive 209, 255, 347, 373, 430, 500, 570 Stationary Steam Engine 37, 145, 266, 398, 497, 639, 746 Half Size Lister ‘D’ 744 Stationary Engine Stress Corrosion 390 Improved ‘Black 5’ Regulator 278, 337, 468 Tempering and Gear Cutters 73, 159, 196, 252, 405 In Praise of the TDI 34 Two Little Engines 376 LB&SCR ‘Terrier’ Tank 489 Wahya 24, 90, 129, 286, 380, 526, in 5 Inch Gauge 629, 749 Little Samson Models 429 We Visit - Ickenham 512 Lockdown Showcase 268, 329 We Visit - Kinver 369 Loco Worth Modelling 94, 155 We Visit - The Cardiff MES 78 Lubrication 464 We Visit - The Hereford SME 201 Making Hexagonal Sockets 456 We Visit - The Tree Tops Railway 729 Simplifi ed Weir Pump 40 Making Loco Name Plates 555 Wenford 43, 162, 261, 394, 508, 646, Making of Hilary Jane 669, 766 736 POSTBAG INDEX Belt Sanders Coles, Tim 741 Carbon Monoxide Palterman, J. 503 Casting Luker 84 TO VOLUME 225 Casting Martyn, Gerald 84 June to December 2020 Casting Shelley, Noel 84 INDEX Casting Shelley, Noel 265 SMOKE RINGS INDEX Colonel Stephens Bauer, John 741 Alexandra Palace Show 488 Colonel Stephens King, Peter 265 Back Issues 428, 488, 608, 728 Communication Cord Fitzgerald, Ron 569 Back Numbers 308 Don Ashton Binning, Andrew 22 Boom Time 368 Don Ashton Hewson, Doug 22 Brass, Steel and Fire 548 Drills Bauer, John 154 Carbon Monoxide 128 Etching PCBs Brown, Peter 742 Christmas! 668 Etching PCBs Chappell, John 742 Coal Supplies 488 Firearms Davison, Chris 22 Cock-up Corner 308, 488 ‘Glass’ Cases Pattison, Chris 741 Covid Cancellations 308 Injectors Gearing, Martin 397 Duff Drawings 80 Injectors Townsend, John 567 Garden Rail Show 608 Lockout Device Backhouse, Roger 397 Gift Cards 668 Lubrication Shelley, Noel 742 Good With Your Hands 308 Metal Fatigue Buck, Jeremy 23 Green Shoots 188 Metal Fatigue Carter, Trevor 22 Greenly Royal Scot 128, 188 Metal Fatigue Walker, Robert 23 How Was It For You? 8 Pipe Bender Brown, D.A.G. 85 In Memoriam 608 Project Success Bayliss, Ian 154 Jack Buckler 308 Projects Astbury, Graham 85 LB&SCR Terrier 488 Prostate Cancer Bauer, John 740 Lockdown II 668, 728 Prostate Cancer Hart, Stewart 567 Lockdown Showcase 128, 188, 248, 368 Pulling the Chain Wakeford, Roger 265 LOWMEX 128 Pulling the Chain Wells, James 265 Lubrication 548 Railway Brakes Gray, Mike 741 Metal Universe 248 Spindle Handles Rousseau, André 265 MINX Loco 548 STEN Guns Collyer, Paul 740 More Haste, Less Speed 548 STEN Guns King, Peter 397 STEN Guns Kirby, J.E. 741 Murdock Engine 8 Suez Crisis Astbury, Graham 85 Mystery Object 608, 668 Suez Crisis Fletcher, Ted 264 Normality 368 Suez Crisis King, Peter 264 Optimism 80 Suez Crisis Wells, James 568 Pembroke 8 Tauco Drill Grainger, John 742 Prescience 80 Trevor Shortland Whittaker, Vic 740 Rip Van Winkle 128 Tube Expanders Smith, Jeff 568 TEE Publishing 428 Tungsten Chromium Steel Wells, James 84 Temptation 128 Valve Gear Design Wells, James 568 Trevor Shortland 548 Vandalism Hockin, Davina 85 Trills and Cadenzas 428 Water Gauges Cleworth, David 85 Unusual Injector 188 Woods Metal Gearing, Martin 397 Valve Gear Design 548 Woods Metal Wells, James 503 Vandalism 80 PART 6 - THE MATURE 150 YearsYears ooff the ALICE CLASS ‘‘QuarryQuarry HunsletHunslet’’ DynastyDynasty
lthough the basic Alice class specification had Mark Abecome established Smithers before the end of the 1880s, celebrates there were still further 150 years of variations on the basic theme to come. In analysing the famous these, we are fortunate in Leeds locomotive the fact that all of the ex- builder. Dinorwic class members have survived intact into the preservation era, although Continued from p.757 not without the inevitable M.E. 4653, 4 December 2020 exchange and replacement of components over the years, both during their initial and post-preservation careers. After 1891, the next major development on the Dinorwic front for the class was W/ Ns 678-9 of 1898, originally named respectively The First and The Second, later becoming Bernstein and Covertcoat. These locomotives were supplied to the Dry Dock Co. for working at the Port and incorporated design modifications consistent with shunting and transfer work there. There being no need for chamfered mainframes owing Britomart class Pen-yr-Orsedd locomotive Sybil, one of four built to its basic to the relatively level ground specification on display in Pontiscill Museum on the Brecon Mountain Railway, having at the Port, these locomotives been restored to working order in 2012. Three locomotives were built exactly to this were supplied with mainframes design for Pen-yr-Orsedd with Jack (Hunslet W/N 684 of 1898)-pattern cabs; second of a similar profile to Margaret generation Alice class mainframes; shallow, only slightly radiused bufferbeams with of the Penrhyn system, closely spaced buffer blocks (since removed), cylinder access holes and handbrake albeit allied to properly supported by the firebox wrapper. The fourth locomotive,Dorothea as built differed rectangular buffer beams. from the other three mainly by reason of its cab design although it was also fitted with Buffers and drawgear of the primitive cowcatchers as built (again since removed). Unlike the other three, its block pattern originally employed buffers have been retained in preservation. Of the four, only Sybil has retained its on Vaenol were fitted. Not original cylindrical sandboxes. initially being constrained by the internal quarry loading to that used on Pearl, later Lancashire Light Railways, gauge restrictions, this pair augmented with a small front the locomotive is now back at of locomotives were supplied sheet. Both locomotives were Lytham St. Anne’s although with tall chimneys and a later transferred to the Quarry nowadays in static form. pair of classic tank-mounted and Bernstein, out of use by Covertcoat was sold to J. L. ‘Leeds’- pattern cylindrical 1966, was sold to J. M. Morris Buttler, Ripley, Surrey on 11 sand boxes, although these in July 1967 for use on the December 1964, later passing latter items were removed later Lytham Creek Light Railway to Nigel Bowman for use on in their careers whilst W/N under the name Jonathon. the Launceston Steam Railway 679 at least was built with a After subsequent spells nearly two decades later. The canopy of similar configuration on the Bala Lake and West locomotive received a classic >> www.model-engineer.co.uk 33 The current Alice, a second generation member of the class, with strengthened mainframes but retaining free standing handbrake column, is seen here at the Leighton Buzzard Railway’s Pages Park terminus on 12 September 2012, having been Sybil’s slightly younger sister, Una is seen in this ‘brought back from the dead’. The locomotive is now based on the Bala Lake Railway view during the 1993 ‘Hunslet Hundred’ Gala. and has more recently been the subject of a children’s book.
Hunslet-pattern cab in 1987; associated with the mainframe in Gloucestershire, later of Ireland. During a subsequent a tender in 1991 and a new configuration of W/N’s 678-9 undergoing a protracted overhaul in 1982, a vacuum boiler and firebox in 2006- did have some influence as overhaul that was completed ejector and steam brake 7, remaining a Launceston a shorter, ‘steeper’ chamfer in the spring of 2017 at were fitted, the former being ‘stalwart’ ever since. The was employed at the rear end. Llanuwchllyn on the Bala Lake replaced by a smaller fitting third member of the 1898 This pattern of mainframe Railway, where the locomotive in 2009, along with a Master trio, W/N 680 Wellington (later became the later Alice class now operates. Mechanics spark arrester. Sybil George B) was supplied to the standard and all subsequent In 1899 came the next stage was sold on 23 September Quarry and sported ‘shallow’ Dinorwic class members in the basic Alice story with 1963 to Tony Hills, eventually buffer beams and draw gear possessed it. George B was the appearance of the 1 foot making its operational debut consistent with its envisaged sold in October 1965 to 11½ inch gauge Britomart in preservation on the Brecon operating conditions. Alan White for operation at (W/N 707) for Pen-yr-Orsedd Mountain Railway, hauling the However, the greater strength the Dowty Railway’s site Quarry in the Nantlle Valley. first trains on this line in 1980. Being devoid of tunnels on The locomotive was stored this system, the permitted out of use, being too small for loading gauge allowed for the normal service, until put back fitting of a standard Jack- into working order in 2012. pattern Hunslet cab, whilst Today it normally resides in the chassis, otherwise similar the Museum at Pontsticill. Una to George B, was fitted with was sold on 8 May 1965 to G. axleboxes and wheelsets made J. Mullis of Salwarpe, Worcs. to suit the slightly wider gauge and re-sold in October 1970 to from the start. Unlike the Tony Hills who subsequently previous Alice class standard, carried out an overhaul at the handbrake column was Llanberis. In October 1977, Una attached to the firebox wrapper was sold again, this time to the as per Gwynedd and the ‘dumb’ Welsh National Slate Museum buffers were more closely in Llanberis, where, apart from spaced. Britomart was followed a few external visits, it has on the Pen-yr-Orsedd system remained ever since. A fourth by two sisters, Sybil and Una variant of this sub-grouping, respectively W/Ns 827 of Dorothea was supplied to the The original Maid Marian and Irish Mail both had differences from the normal second 1903 and 873 of 1905. These neighbouring Dorothea Quarry generation Alice class specification. That of the former locomotive could arguably three sisters remained at as W/N 763 of 1901. The constitute a radical alteration as its domed boiler adulterated the ‘pedigree’ of the Pen-yr-Orsedd until the 1960s, main differences between this domeless Wilsonian-derived boiler normally associated with the class. It was allegedly with Britomart being sold to locomotive and the Pen-yr- fitted to facilitate easier working of the Dinorwic system’s Allt Dhu (or Village) Tramway. a consortium of Festiniog Orsedd trio were the fitting of Signficantly,Maid Marian’s waist sheets had angular corners as built, which supports Railway personnel in June shallow ‘cowcatchers’ and a the generally held view that the upper cab (Britomart/Sybil style) was originally 1965. Following an overhaul cab with radiused rectangular intended for this locomotive, although it was fitted to Irish Mail. Both locomotives the locomotive returned to cut-outs in lieu of the curved incorporated Britomart’s firebox wrapper-mounted handbrake andIrish Mail, by reason working order the following profile.Dorothea was last noted of its domeless boiler can be regarded as the first true ‘third generation’ Alice. Its upper year, with a blue colour working in December 1941 cab (not further repeated on the class as built) has been restored in preservation on the scheme inspired by that used (latterly with a chimney rather West Lancashire Light Railway as can be seen in this view. on the Great Northern Railway akin to a drainpipe) and the
34 Model Engineer 18 December 2020 QUARRY HUNSLETS
suffered the indignity, during the 1960s, of being used as a potential source of parts for the restoration of other ‘Quarry Hunslet’ locomotives after its shed had collapsed. The boiler and mainframes departed the site in March 1970 and, after years in storage, these and other retrieved components were sold to Kay Bowman of the Launceston Steam Railway in 1989. Initially steamed in 2001 using Covertcoat’s boiler and saddle tank, Dorothea had its own boiler and tank restored in time for another steaming on 13 November 2011, before re-entering service, fi tted with air braking equipment, during Easter 2012. The practice of mounting the handbrake column on The present day King of the Scarlets is widely thought to contain most of the original surviving material from Maid Marian the fi rebox wrapper did not as built including the fi rebox mounted handbrake column, but today the locomotive has a standard Alice-pattern domeless immediately rub off on the boiler (thereby effectively making the locomotive a third generation Alice, apart from its current early waist sheet design). locomotives built for the Repatriated from Canada in 2012, the locomotive has not undergone any subsequent restoration and it is seen here on display Dinorwic Quarry and the next at Statfold Barn on 9 April 2016. The ‘third generation’ cylinder access holes (also found on Irish Mail and Thomas Bach) also two in our story, W/Ns 779-80 add weight to the view that the chassis of the engine is predominantly the one originally fi tted toMaid Marian. of 1902, originally No. 3 and No. 4 respectively, later Holy prior to re-entry into service. and reconditioned for Irish Mail. The next pair of Dinorwic War and Alice, reverted to the The locomotive passed into By 1977 the frame components locomotives were of free-standing arrangement the ownership of the railway had migrated to the Bala Lake signifi cance in that although with no cab. Holy War earned company in 1989. Alice had Railway where they were they followed the basic the distinction of being the last a much more tortuous route re-united with others that contemporary pattern, they had steam locomotive in normal to recovery following use had been initially acquired to specialised characteristics. work in any slate quarry in as a source of spare parts repair Holy War. In 1987 sale to W/N 822 of 1903 No. 5 (later Britain, fi nally being taken out for other locomotives in the Chris Scott followed and after Maid Marian) carried a polished of service in November 1967. quarry following withdrawal some time in store, Alice was brass dome on the saddle It was sold to J. M. Hutchings by February 1961. In 1972 the moved to the Leighton Buzzard tank, rectangular corners to on 20 March 1970 and sent to boiler and frame assembly, Narrow Gauge Railway, who the fronts of the waist-sheet Quainton Road, being re-sold which had been ‘marooned’ fi nanced a new boiler to allow assemblies and a handbrake to the Rev. Alan Cliff in 1975 at 1600 feet above sea level the engine to re-enter service column supported by the for passenger operation on on Dinorwic’s Australia Level, in 1994. Returning to the Bala fi rebox wrapper.Maid Marian the Bala Lake Railway, where were lowered down inclines Lake Railway in 2003, Alice spent the fi rst quarter of a it has been based ever since. to enable transfer to the West was purchased by Julian Birley century of its career working on Apart from the normal pattern Lancashire Light Railway, seven years later and is now the Allt Dhu Village Tramroad of repairs, a cab was fi tted where the boiler was removed based on the Bala Lake system. prior to transfer to the quarry at which point matters get rather complicated. What is known is that the locomotive bearing the name that was purchased by the Maid Marian Locomotive Fund following withdrawal in the early 1960’s is not predominantly W/N 822. Most of its chassis components appear to have been swapped with W/N 492, as evidenced by its surviving components. This view would be given greater weight by the fact that what purports to be W/N 492, although today fi tted with a domeless boiler, has a fi rebox-supported handbrake A right hand view of King of the Scarlets taken on 16 May 2017. column and ‘second generation’ >> www.model-engineer.co.uk 35 mainframes. Be that as it may, the current Maid Marian was transferred to Bressingham Steam Museum on 3 May 1968, migrating to the Llanberis Lake Railway three years later and around this time the necessary re-gauging and alterations for passenger working (such as the fitting of a cab and conventional buffers) were carried out. In 1975 the Fund moved Maid Marian to the Bala Lake Railway where the locomotive has remained ever since. In the winter of 2016-7, the original pattern buffers were restored and for a while, early pattern waist-sheets were fitted, but the cab was re-fitted in time for the ‘Hunslet 125’ Gala of May 2018. The true scope of the ‘parts swap’ between King of the Scarlets, Maid Marian, Velinheli and (possibly) Lady The last true third generation Alice class locomotive to be constructed, Wild Aster (now Thomas Bach) is seen here under Madcap is not known for overhaul in the workshops of North Bay Railway Engineering Services Ltd. in February 2020. This view emphasizes the certain today. What is known Britomart-pattern firebox-mounted handbrake column. By the time of writing the overhaul had been completed and the is that Maid Marian had a engine was ready for return to its base at the Llanberis Lake Railway, fitted with a Holy War-style cab. replacement (domeless) boiler and welded saddle tank when with Pamela) and would have of 1904 No. 7 later Wild Aster. lubrication and a later sold from Dinorwic; King of entailed removal of the firebox This locomotive was cabless Dinorwic Port-class inspired the Scarlets was as described stretcher, relocation of the and domeless as built and cab, lengthened and sitting on above and Velinheli was expansion bracket mountings, fitted with a firebox-mounted a footplate extended over the fitted with a domed boiler in construction of a new ashpan handbrake column and rear buffers, Manning Wardle 1952 that was a replacement and extensive modifications rectangular-cornered waist Sunbeam fashion. More (presumably intended for to the smokebox and front sheet assemblies. It was out recently bearing dual Thomas Maid Marian in original form) tubeplate. Once again, all of of use and dismantled by Bach/Wild Aster identity, the built in the Dinorwic Dry this was theoretically possible, February 1962, being sold in locomotive has undergone Dock Co.’s workshops in but definite proof of its 1969 for use on the Llanberis an overhaul in the workshop 1925. In addition the original happening is lacking. Lake Railway. In 1988, W/N of North Bay Railway Maid Marian’s waist sheet W/N 823 of 1903 No. 6, later 849 returned to service as Engineering Services Ltd. in assemblies were apparently Irish Mail was, unlike W/N 822 Thomas Bach fitted with Darlington in 2020. fitted. It is claimed thatLady built with a cab but no dome. steam braking, mechanical lTo be continued. Madcap was temporarily fitted The upper cab was soon taken with a smaller ‘3 foot 3 inch off in service and by 1959 the wheelbase’ boiler and tank in boiler had been removed, with 1931 and the possibility has the chassis being auctioned been raised that these were off to members of the West the original items from Maid Lancashire Light Railway Marian, given the fact that Lady on 18 December 1969. Madcap was transferred to After restoration to working the Allt Dhu Tramroad at this order completed in 1981 the time. On the face of it, there is locomotive has become a one argument that stands out: mainstay of the W.L.L.R. fleet. the two names have the same Throughout its quarry life, the number of letters and word lower part of the cab remained lengths, so replacing the name as supplied incorporating the Lady Madcap on Maid Marian’s bottom parts of the cut-outs. old tank would have been An original pattern upper cab, theoretically possible without although unclear in purpose on drilling any more holes in the the engine as built, has been tank. As for the difference in refitted in preservation. boiler barrel length, this would The final trueAlice class This 5 inch gauge model of Wild Aster as built showing the original have had to have been catered locomotive built for the Maid Marian-pattern rectangular waist sheets with which the full-size for at the firebox end (as Dinorwic system was W/N 849 locomotive ended its career on the Dinorwic system.
36 Model Engineer 18 December 2020 GarretGarrettt 4CD TTractorractorPART 77 in 6 inch scale
This article has been written to guide the builder through the construction of the 6 inch scale Garrett 4CD tractor designed by Chris d’Alquen. The writer has previously built a Chris Gunn 4 inch scale Garrett and a 6 inch scale Foden wagon so has the benefit of considerable splits the experience in larger scale modelling. Most machining can be done in the average home canopy and workshop but the supplier from whom the castings and drawings are currently available adds a seat is able to provide a machining service for the largest items if required. and a pair of footrests.
Continued from p.675 n this part I will cover some it, the mileage would still be each ramp and lock the ramps M.E. 4652, 20 November 2020 points arising from making reasonable. There are any to the van tow bar support Ia 6 inch scale engine and number of ex-lease vans on using a shackle. I was now also matters arising from offer from local van dealers able to winch the engine into the first two years rallying it. and online. However, their the van safely and it was great The first item I will cover is modus operandi seems to be to be able to stand up inside transport. I used to take my 4 the same; they will buy vans the van, something I could not inch Garrett and a caravan to from the leasing company do in the HiAce. rallies using a Toyota HiAce and advertise them. Once I could now sell the HiAce van. This van was purchased they get a buyer, then they and got £1,100 for it, sight by the company I worked for will get the van ready. If there unseen, from a local van in 1994 and it was used by are significant problems the dealer. It fetched such a good our service engineer. When I dealers have to sort them out, price as it was to be shipped retired in 2004 I bought the van but I had two bad experiences to the Caribbean as spares for and ran it until 2016. During when the dealer could not sort the fleets of old HiAces that that 22 year period it covered out the problems cheaply, so serve the area as mini buses. 160,000 miles and never ever pulled out of the deal. However, I loaded the van and took it to broke down. I was reluctant to I got one (third time lucky) the local weighbridge and was let it go, but it could not take which turned out to be suitable just inside the limit. However I the new engine so I researched so far, although I did have to did not have space or any spare its replacement. I did not have some work done on the capacity for a trailer, so that want a really big van; I wanted brakes at the MOT. was one big change. something Transit sized. I I now had a van big enough I used to tow a trailer behind checked all the specifications to take the engine but I had my small engine to carry extra on line and produced a to fit a higher capacity winch water and coal and also to spreadsheet of the various and I chose one from the give rides behind the engine. attributes. I soon found out Machine Mart Ninja range. I did make a towbar which that the payload of 3.5T vans I tried the new engine with would allow me to still use did not necessarily increase my old aluminium ramps but the small trailer if it were as they got bigger. I needed a they sagged a bit under the available. What I also found 1.5T payload if I could get it, heavier engine, so that meant was the additional water to cover the engine and the a new set of ramps. I saw an capacity of the 4CD, with the rally kit. In the end I went for a advert in Old Glory magazine big tender and belly tank, plus long wheel base Transit on the and ordered a pair. These were the bigger coal capacity meant basis it gave me the payload heavy duty steel and were that the engine has a longer I needed and there are plenty perfect for the job. I once had range than the small Garrett. I of them about. Buying one a bad experience with ramps found that I could do my usual was not as easy as it could with my smaller engine when runs around the rallies and still have been. I did not want to winding it up into the van using have water and coal available. buy a low mileage van from a the flywheel; the wheel pulled As the engine is a compound Drawings, castings and main dealer as I knew the van the ramp off the van instead of it should, in theory, be more machining services are would only do a few thousand running up it. Since then I have efficient, which might give me available from A. N. miles a year. I felt I could get always secured the ramps to more miles per gallon. Engineering: Email: a higher mileage one and by the van and this time I was Now I was all set with my [email protected] the time I had finished with able to fit a piece of chain to transport, the engine was >> www.model-engineer.co.uk 37 663 664
Tender try cocks. Belly tank bypass. rallied through the 2016 never seen an engine fitted the day it takes a lot longer to right of the globe valve with season and my general this way, or heard much about cool down. One needs to plan the red handwheel. impressions were as follows. it since. accordingly when the engine The handle is shown in the The 4CD is heavy. Empty I found the fire easy to is being transported in an closed position preventing it weighs in at 1,030kg or light and fast to draw and I enclosed van. water flowing and needs to thereabouts and while I am could get pressure up quite I found that the engine will be turned 180 degrees to able to push it along on my quickly. However the firebox make steam readily with any allow the water to flow. I then own on my paved drive, it swallowed a lot of coal. The coal (steam or household) start filling through the belly is not so easy on grass and hinged firehole door was a lot and seems to quite like the tank filler (there is no filler on worse on soft grass. My usual better than the sliding one on household coal when lighting the tender). When the water procedure at a rally was to the 4 inch Garrett. Once steam up. I also found that if I had trickles through the bottom park the caravan, then put was up, I found the throttle a really hot fire using good try cock, that is closed and I the van next to it, unload the somewhat insensitive and that quality steam coal, it would keep on filling. When the water engine straight out of the van it was hard to set the engine steam for a long while when trickles through the top try and turn it through 90 degrees to a slow tick over. The other running around. cock, that indicates the system and park the engine in front problem with the throttle was I seemed to have more range is almost full, but I can still get of the caravan. When I tried the direction of travel. In my with the 4CD as the belly tank at least another 15 litres in. If this with the 4CD I found it little Garrett the throttle is makes a big difference. The I want it really full I keep filling impossible to push the engine opened by pushing it forward tender holds 32L of water until the water starts to seep round to where I wanted it in the direction of travel, which when full to the brim and the onto the footplate, then I shut and quite difficult to move by has a certain logic to it. On the belly tank 35L. The belly tanks the belly tank bypass and keep turning the flywheel, even with 4CD the throttle is opened by should double the range of filling until the belly tank is low gear engaged. pulling the throttle towards the engine. I had to learn to completely full. It takes a while I decided that I would the driver. It took me a while to manage the water transfer to completely fill, as once the change my methods, so I park re-educate my reactions. I have from belly tank to tender. water is up to the curved top of the caravan, then position my to admit that a couple of times The belly tank top is higher the tank it is effectively divided van so the ramps will deposit when I needed to make an than the tender top, so if the into two compartments and the engine right outside the emergency stop on the 4CD I tender is filled to the brim the water can only flow into front of the caravan where I pulled the throttle towards me and the bypass valve is left the LH side of the tank as fast want it. This is fine when folk which had the opposite effect. open and the belly tank filled as the air can get out. There are not trying to park another I am used to it now and I will to the brim as well, then the is a breather to allow this to caravan next to me. I found be fine until I get back on the water will seep through the happen and when the water that if I got to the rally site a little one. holes in tender top where the finally settles, then I know it is bit earlier then this was not a The engine is much heavier pump pipes go through and full to the brim. I always make problem. As I am retired, I am with a bigger fire so it does not flood the top of the tender and sure I am really topped up if able to get to the site early need as frequent attention as eventually overflow. I am going on a run around. I enough to make this possible. its smaller brother and it will I empty the tender and belly have learned to open the belly When the rally ends one at sit for an hour with little drop tanks before transporting the tank bypass after some water least has the benefit of some in pressure if it has a good fire. engine as this saves 75kg of has been pumped, so the belly steam to get the engine behind This makes it easy to stop for my payload. When I fill it up tank can empty. If I do it too the van in the loading position! lunch without losing the fire. I open the two (commercial) soon the footplate is swamped I have read somewhere of As the engine is much try cocks on the tender (photo and I waste the water. attempts to use a caravan heavier, there is a lot more 663). I also open the belly When I am rallying the motor mover to move a heavy metal to warm up. With a tank bypass valve as shown in supply of water is pretty engine by driving the flywheel bigger fire this does not seem photo 664. The bypass control important and this can be with a rubber roller. I have a problem, but at the end of is the L-shaped rod to the a bit hit and miss. One may
38 Model Engineer 18 December 2020 GARRETT 4CD TRACTOR have to fi ll up containers at a After two years of rallying 665 tap, or sometimes a (usually the engine a number of items historic) fi re engine will drive cropped up which needed round and fi ll them for you. attention or changing. Sometimes we get a palletised I mentioned before the bulk container raised up for water pump gear change, us. These usually have a fi erce which allows the water pump tap on the bottom to fi ll the drive to be disengaged. cans or containers. (As long This was not on the full size as no-one uses the containers engines but felt to be a useful to empty their toilets these addition. In practice however, I are fi ne.) None of these water can say I have never used this supply solutions make it feature in two years. I tend easy to use the water lifter. I to use the pump to keep the was once able to fi nd a horse boiler topped up and when the trough to try my water lifter boiler is full I use the pump and I was gratifi ed at how bypass to stop the boiler fast it fi lled the belly tank, but overfi lling. I use the injector there was not much fi nesse occasionally if I have to put Tender breather. about it. I made the water a lot of water in, but I like to lifter from bits and pieces and use the pump as it is easy to removed with the breather in I also had some wear on made an educated guess at check it is working. The pump situ (photo 665). some of the linkages and may what it looked like inside and has been absolutely reliable Still with water, I noticed a well have contributed to this it worked well. and so far has never faltered. puddle under the engine and by using thin oil of uncertain As far as driving the engine If you intend to work this observed that this was dripping properties. I have had to is concerned, it has plenty way then maybe making the from the pump. This would deal with the worn items of power, more than enough gear change is not worth the happen whether the engine was as described below, but the to carry two on the seats effort. I think if I was starting pumping or the pump bypass engine seemed to run sweeter with power to spare. I tend to again, I would not do it. The was open. I had noticed on and quieter when I switched trundle around the rally fi eld information is there whichever a few full size engines with to Golden Film 460 bearing oil slowly in low gear so I can way you choose to go. pumps mounted over the from Morris Lubricants. This react when someone walks in While on the subject of water, tender like this one, that a drip is a much thicker, stickier oil front. If a bit of extra power at one stage I convinced myself tray was provided to catch the which is formulated for the job. is required momentarily, the that the water was not fl owing drips and return them to the The downside I had after simpling valve can be pressed fast enough from belly tank to tender and thought this was a few rallies was that the and the power is boosted tender. I deduced that as the worth doing. I was able to make engine seemed to be on the signifi cantly. I have tested it tender was pretty well a closed a small brass tray (photo 666), noisy side. This could be in second gear and it is plenty tank, I needed to add a breather fi t it to the pump feed pipe and diagnosed as coming from fast enough on grass. On a few to the tender. I opened up a connect a pipe to take the drips the motion, but with so many road runs I have had it going as hole in the corner and tapped it back to the tender. moving parts on the engine fast as I felt comfortable with. 1/8 inch BSP and then installed I did mention how I modifi ed it was diffi cult to zero in on It will run along very smoothly an Enots fi tting and a piece of the oil pot lids by adding fl ip exactly where the noise was and is a joy to drive. It is more ¼ inch tube bent over at the top or ball type oilers on most coming from. The engine was pleasurable because one does top to act as a breather. I cut of them as unscrewing 20 not fully run-in as far as I was not have to be fi ddling with the a clearance in the top plate of was time consuming. This concerned, especially when I fi re or the water all the time. the tender so the plate can be proved to be a waste of time was able to compare it with as my oil can could not pump another fully run-in engine; my 666 the lubricating oil through engine seemed much stiffer these quick enough. When I when turning the fl ywheel. I switched to a thicker oil this loosened up the main bearings was impossible. The only a touch and that made things benefi t I found was that if I better, but it was still on the dropped an oil pot lid then I noisy side. I had to ask some could use a magnetic pick of my colleagues to have up tool to fi nd it in the grass a look and listen and the or from between the side of consensus was that the noise the boiler and the horn plate. was coming from the valve Therefore I would not bother gear. Accordingly, when I got to do the oiler modifi cation, back from the rally in question, but I would seriously consider I dismantled some of the valve making the lids from steel or gear to see what I could fi nd. adding a steel bolt to a brass What I found was a lot of slop lid. I would also advocate right through the valve gear. I making a few spare lids as I also knew the reversing lever did have had one or two fl y off was fi tted the wrong way Pump drip tray. when they unscrewed. round, with the latch facing >> www.model-engineer.co.uk 39 forward. I dealt with that fi rst engine too and I imagine the as it was simple to reverse loads on the bearing and pins 667 the lever, but this then threw are higher than I expected. the reach rod length out of Fortunately, there is plenty of kilter. Luckily I had made the meat in the eccentric rod forks, reach rod in three parts, with so I carefully set them up in the a pair of straps connecting Bridgeport and opened out the it to the lever. I was able to holes and fi tted bronze bushes. make a new pair of straps to This tightened up the joints connect the lever to the reach considerably. rod and make sure everything While the eccentric rods connected up as it should. were apart, I also noticed Photograph 667 shows the there was slop between the lever after the modifi cation. eccentrics and their straps in Once I had disconnected the three out of the four. I felt I had eccentric rods, I noticed there to deal with this as well and I was quite a bit of slop in the skimmed a few thou’ off the pin holes in the eccentric rods. joint faces which tightened I had not hardened the pins or them up to my satisfaction. Reversing lever. the holes and I think this led to The die blocks were also premature wear at this point. loose in their slots. I had used in the big one they seemed to The pins were not worn but the a fi lled textile based material, have worn. I made a new pair in NEXT TIME pin holes were. This may have ‘Orkot’ for this as I had on my gauge plate and hardened them I’ll wrap up with a visit to been exacerbated by the wrong little Garrett, where they still and this was another job done. another rally and a few last oil being used. It is a powerful are after 17 years. However ●To be continued. problems to fi x.
No.300
The next MEW is our 300th issue!
In celebration we will have some special contributions from some of our past editors and a nostalgic look back at over 30 years of your favourite magazine, as well as all your usual favourite content.
On Sale 8th January 2021
40 Model Engineer 18 December 2020 PPetroletrol Engine PART 4 and Alternator SetSetss HoHoww ttoo makmakee them wworkork wwellell and why thetheyy ooftenften don’t
The first live tests The original plan was to 16 Jon incorporate all this kit into a 5 Freeman inch gauge locomotive chassis explains to demonstrate performance how to on the track. However, due to pandemic lock-down, all early make petrol system testing happened in engines and electrical the back garden using a test alternators work load, consisting of low voltage efficiently together. filament bulbs. Photograph 16 shows the test load. This started Continued from p.765 off having five switchable M.E. 4653, 4 December 2020 pairs of 60W, 24V filament bulbs to allow the unit to be tested under a variety of load conditions from zero up to Test load. 600 watts. The extra bulb on its own was a late addition, The first live ‘engine running’ were switched on. With each not switched, connected at all test was using the alternator increase in load the engine times. This serves to prevent, with its original regulator. With revs fell but output remained or at least absorb, some of the just the single 24V 60W lamp above 12 volts. The load energy from any high voltage as load, the engine started and power was not measured, but transient output of the sort delivered close to 14.5 volts filament lamps at half voltage typically delivered by these over the full engine speed consume rather more than alternators when loads are range. Then with the revs set half power due to the lower switched. as high as possible, extra loads temperature and hence lower resistance. Maximum power was probably in the region of 17 400 watts. When attempting to lower engine revs, a small reduction was possible before the engine stalled. Repeating the test with fewer load lamps energised gave similar results with the engine stalling from lower speeds. All as predicted. The original regulator was then removed and the new smart regulator wired in (photo 17). Not having a set of traction batteries to hand, a small 12V battery was connected to power the electronics and energise the field before the alternator output rises enough for The whole lash-up ready for testing. energisation to be self- >> www.model-engineer.co.uk 41 sustaining. The digital ammeter on the new smart- Fig 14 regulator board was wired into the output, this, and much else, being readable on the screen of a laptop connected via USB. The laptop runs ‘PuTTY’, a terminal programme which connects to the smart- regulator and allows exchange of commands and information between the two. This makes table tweaking and all sorts of diagnostics quick and easy. The field current limiter lookup table was initially set to 0% for all speeds below 3000 RPM and to 100% for all speeds above. This is shown in fig 14. This would arrest any plunge towards stalling by removing nearly all load at speeds below 3000 RPM (but this only becomes useful once the Lookup 1. microcontroller code to read engine speed has been proved). The microcontroller programme mechanical switches. This a copy of the timer is made. distance. The control loop code at this early stage was works by reacting to the first Subtracting the previous repetition rate was not too simply configured to make the transition of the ringing signal, reading gives the number of fussy, but fast enough to not engine control servo track the then blanking any subsequent microseconds between engine cause jerky control actions so ‘driver’s pot’ potentiometer. transitions that occur during pulses. Converting this to RPM a rate of 12.5 times per second a set time period - the ‘de- is simply : was adopted. Engine speed is measured bounce window’. The simple Engine speed control can be The engine speed interface circuit is shown in RPM = 60,000,000 / pulse made to work quite nicely by measurement code was photo 18. The 10kΩ resistor repetition interval in adjusting the size of correction debugged first. The magneto limits current taken from the microseconds applied on each pass through is driven from the crankshaft, engine to something too small the control loop - too large therefore it creates twice as for it to notice and the diode This division fits a single tends to instability, too small many sparks (and pulses) clips the pulse voltage to levels 32 bit machine instruction gives a sluggish response. The as needed for a four stroke required at the microcontroller. which takes a fraction of a servo was seen to be keeping engine, providing one pulse per One of the numbers in the user microsecond to execute. very busy, making rapid, small rev (not that it matters a jot set-up is MAX_RPM. From this hunting movements in either sparking the plug at the top of the controller calculates the Engine speed is controlled direction. This was quietened the exhaust stroke). ideal de-bounce window time. With engine speed down by building in a small To convert the ringing Making good use of measurement proven, the dead-band by not making any pulsed magneto signal (see microcontroller resources, a next step was to use this as corrections for speeds within photo 12, part 2) into a form timer is set up in code keeping feedback in a loop to control ± 2% of that desired. This is useable by the microcontroller, a record of the number of engine speed. A test function close enough for our needs and a ‘digital de-bouncer’ is microseconds elapsed since was coded to enter desired should result in a reasonable employed. This is of the type last powered up. Each time a engine speeds using the laptop life-span for the servo. used for reliable reading of new engine pulse is recorded and USB link. With the engine To keep the software as running, several test speeds versatile and flexible as were entered, the resulting possible, for use with any 18 engine speed being reported engine alternator combination, back and displayed on the a second, generic speed-setting laptop once per second. With function was coded. With these aids in place the control tickover and useful minimum, algorithm was soon tamed and maximum, engine speeds and de-bugged. In a section of now set in eeprom, the new code executed several times function takes a number per second, the measured from 0 to 100 as the desired RPM is compared to the ‘RPM percentage up the useable requested’, the difference speed range. Sending 0 sets being the ‘RPM error’. This the servo to the end of its travel error signal is used to move – tickover - when no power is Engine interface. the engine control servo a tiny needed. Sending numbers from
42 Model Engineer 18 December 2020 ALTERNATORS
Engine speed control can be made to work quite 19 nicely by adjusting the size of correction applied on each pass through the control loop - too large tends to instability, too small gives a sluggish response.
1 to 100 set the speed to that alternator effi ciency of 50% many percent between useful had been assumed, and this minimum and maximum. This output suggests 55% had function performs a simple been achieved, there are good arithmetic conversion to actual technical reasons to expect RPM and feeds the result to the higher effi ciency with higher original speed control function. output voltages. The engine This provides a clean and power was the limiting factor, simple interface for whatever screaming at maximum revs locomotive control algorithms close to 7000 RPM to deliver Running and delivering over 400W at 25V. are later thought up, none of this. A larger engine could which will need to know any have given higher throughput. standardised numerical form background, the task of coding details about engines. There seems no good reason for higher level functions to the really interesting parts is why output currents could not read and act upon. Once coded made a lot easier. The fi nal Torque limiter testing go as high as stated in the and debugged, these functions code will allow the user to After connecting the fi eld Lucas manual. Nevertheless, were locked away with no select one of several operating winding, tests resumed. This as it stands this would be further need to worry about modes and one selected for time alternator output was suffi cient to power a chunky how they worked. A timer early work was a ‘current produced, and a voltmeter locomotive in fi ve inch gauge, is set to ‘tick’ one thousand mode’, where engine speed showed an output of 25.4 with or without batteries times per second and, on gets set according to the volts, proving that all circuits (photo 19). each tick, the lower level current being drawn. The code around the PWM control chip functions are sequenced with for this is shown in fi g 16, the were working as expected. Building a outputs updated. The engine point being to show how little Connected to the test load structured program speed control loop described of it there is! rig, the engine could be set Using a structured ‘C++’ above was morphed into a Final perfecting of control to a speed and the effect of programming style, functions bare-bones ‘engine manager’, algorithms can best be done load changes could be seen. were coded with uniformity checking measured engine once a locomotive is together This showed the engine speed and simplicity of use in mind. speed against requested speed and regular track access control to be very effective for Lower level functions take and making any adjustments restored. All the hard work is all load levels below overload! care of all that’s needed to necessary to the servo. done, all the theory proved in Beyond overload engine speed read voltages, currents, speed With all of this happening practice. Engine and alternator and output voltage fall. etc, and present output in a automatically, unseen in the can be made to play nicely With an unmodifi ed alternator the engine would have stalled. For any given Fig 15 speed, what power level this overload level is now depends on numbers in the lookup table. Much experimenting with lookup table entries followed in the attempt to match engine and alternator torque characteristics, and to maximise power output over the range. Further work on this is likely to bear fruit but a set of numbers producing a table plotted in fi g 15 produced interesting and useful results. Using the smart-regulator onboard ammeter, output currents up to 22 amps were recorded with voltage not below 25.0, an output power of 550 watts. This was slightly Lookup 2. disappointing as although an >> www.model-engineer.co.uk 43 together. At this point, using the current feedback controller Fig 16 of fig 16, at a lower power, the system appeared to work just the same and just as well as the inverter generator had, but with the benefit of revs falling to tickover on no load. Other Code fragment. control methods awaiting the finishing touches are for fixed voltage with or without battery Test result ‘spider’ between the two this too broke. A mild steel systems, variable voltage Happy with the electronics, not halves. For some reason it bar 30mm diameter used for without battery systems, and so with the mechanicals. broke in next to no time. The the new coupler had a 6mm no doubt others will flourish The test rig was very noisy, rig was re-configured to use silver steel pin through each or wither. Such is the nature of so much so it had already a longer coupling shaft, the end, projections fitting suitably ongoing development. There been decided this engine was thought being that perhaps milled slots in the coupler are many possibilities, and a not going to be built into any a longer shaft would better cups at either end. Three of the sound framework of proven final locomotive design. Due accommodate any slight four pin ends have been found engine and alternator control to earlier problems the rig misalignment. Too noisy to broken! This brought all work to is in place. Perfecting simple had been modified. It began start with, the new arrangement a halt - a pause for reflection. algorithms to sit on top of this using a much shorter coupler seemed even louder and, after will be the easier task. with a neoprene or rubber only a few hours of testing, lTo be continued. SHOSHOWCASEWCASE 1918 Morgan Grand PPrixrix ThreeThree WheelerWheeler
I acquired the full-size car as a ‘barn find’, absolutely complete and original, and restored it, probably the only example to survive thus. There are a number of examples in existence now but are mostly re-creations from original and newly made parts. However, before it went I prepared a detailed scale drawing on my CAD system having a possible model in mind. Apart from the ‘Grand Prix’, I have built a 3½ inch gauge GWR ‘Saint’ and a 5 inch gauge Horwich ‘Crab’, both of which run ere are a couple of pictures of a The ‘Grand Prix’ was produced from at the Bristol Model Engineers’ Club track. Hmodel of a 1918 Morgan Grand Prix 1914 to the mid 1920s to commemorate I have also built another Morgan Three Three Wheeler to ⅛th scale which I have Morgan’s win in the 1913 Cyclecar Wheeler model, to ⅛th scale, for which I had in build for several years. As for many International Grand Prix, held at Amiens in was awarded a Gold Medal at the 1986 others the ‘lockdown’ gave me a lot of France. The driver was W. G. McMinnies. Model Engineering Exhibition at Wembley. extra workshop time so accelerated the It was superseded by the Morgan Aero as model to completion as shown. their sports model. Terry Phelps
44 Model Engineer 18 December 2020 PP22 LLocomotiveocomotive Frames Getting Framed!
he A1 Steam Locomotive Trust (A1SLT), builders 1 Graham Langer Tof Peppercorn Class traces the design and A1 PacificTornado , are fabrication of the frames assembling a new Gresley for the new-build P2 Class P2 Mikado 2-8-2, No. Prince of Wales 2007 Prince of Wales, at . Darlington Locomotive Works (DLW), supervised by Director of Engineering, David Elliott. The work involves the use of technology and techniques that have been developed since the original locomotives The initial CAD for the frames of the new P2 (grey, original P2; yellow, were constructed, many of modified P2; red, fabrications instead of castings; green, from No. 60163). which are in common use by model engineers, including use of polystyrene patterns, guides and, to address ride Computer Aided Design (CAD), welded fabrications rather than issues and reduce the risk of laser or water-jet cutting, CAD castings and welding rather derailment, the post-war V2 machining and profiling, the than riveting for the boiler spring side control pony truck construction. was drawn in 3D and applied 2 The main frames were (this involved significant designed in 3D Solidworks changes to the V2 design). with the Cartazzi hornblocks Other changes in the design and additional details of spring mainly involved adapting the gear added to the drawing design of the frame stretchers (photo 1). Materials were to accommodate such items specified and an order for the as a pair of air pumps for the main frames placed with Tata brakes. The order covering Steel. The main frame plate manufacture of the main thickness was set at 30mm frame and tender plates, 1 in lieu of 1 ⁄8 inch as was plasma cutting, grit blasting done on Tornado. Two major and priming was processed changes had been made to the by TATA Steel and these were original design, the adoption rolled at their Scunthorpe of roller bearings and their works 23 April 2014 (photo 2) associated cannon boxes and were profiled on 21 May. The frame plate being rolled at TATA Steel. required changes to the horn Boro’ Foundry at Stourbridge were contracted to machine the edges and drill holes 3 4 in the frame plates. The leading frame extensions were simultaneously being machined on a gantry mill. The left and right-hand plates were tack welded and clamped together on the machine table so that they could be machined and drilled together. All the edges of the profiled frames were machined to remove the metal that was The frames of No. 2001 Cock of the North, set up The frames of No. 2007 at a similar stage. heat affected by the flame at Doncaster Works (photo: A1SLT). cutting process. Typically 0.25 >> www.model-engineer.co.uk 45 inch was removed around the edges in 2.5mm deep 5 cuts. (Apologies for mixture of imperial and metric units – the drawings are imperial, the machine metric!). After the plates were accurately set up on both machines, cutting was Computer Numerically Controlled (CNC) from a .dxf drawing which in turn was derived from the Solidworks 3D model of the locomotive. The result was a set of the most accurate locomotive frames ever produced, the proof of which being at the ‘sandwich’ of three plates for the Cartazzi truck where a finger run across the join could not detect the edges between them! (photos 3 and 4). An order was placed with Bakers Patterns Limited of A multitude of poly patterns for stays and gussets. Telford for all of the existing design frame stay and Cartazzi welds and surrounding areas 6 horn block polystyrene to relax. Because the welding patterns, the castings from process involves adding metal which were needed as soon quickly and cooling rapidly, the as the frames arrived at contraction of the welds leaves Darlington Locomotive Works. significant residual stresses in The decision was taken to the surrounding metal which change the manufacturing in a high fatigue environment method of four of the large can result in cracking. Stress frame stays which provide relieving as the name implies substantial resistance to releases these stresses ‘racking’ of the frames – this is in the structure which will the tendency for one frame to give it strength and fatigue try to move fore or aft relative properties at least equal to to the other one under heavy and, in many cases, better than piston forces – the original the equivalent casting. Some components were made as changes to the shape of the Some of the resultant castings. steel castings. The shape and frame stays were necessary to size of them precluded the enable them to carry air pumps being by driven bolts, where such an area, where a number use of expanded polystyrene and air brake cylinders instead a machined bolt is made very of pipes have to be routed patterns and the cost of using of the vacuum brake cylinders slightly bigger than the hole it along the inside of the frames wooden patterns was very fitted to the original P2 class. fits in and is driven in, either past the ash pan. high as all four frame stays Following delivery to DLW, using a hydraulic jack, or if North View Engineering are different, meaning that the frames were set up not practicable, a large copper in Darlington had been busy we would only cast one off on stands and joined with mallet. A self-locking nut is machining the cast stays each pattern. Compared with temporary stays made of then fitted. This way the bolts and gussets and as these what was available when the threaded rod. At this stage act as dowels and are very were delivered they were P2s were first built, welding the main frames had to have resistant to shear forces which progressively fitted to the techniques have improved a joggle added at the front tend to be the predominant frames (photos 5 and 6). Larger enormously enabling reliable of the Cartazzi truck and this loads in locomotive frames. castings, such as the massive fabrications to be made to was achieved by using a lot of The nuts provide a strong rear drag box (photos 7, 8 and replace castings. To produce heat and a bending moment clamping force as well. 9), were being machined by high integrity fabrications full applied by the works’ forklift The resultant joint is very Multi-Tech in Knottingley and penetration welding to boiler truck! The outer Cartazzi predictable in terms of forces William Cook Cast Products, standards was specified and frames had been pre-formed and quality. The only places principal sponsor of both each fabrication was fully and could now be bolted where retaining rivets were No. 60163 and No. 2007, stress relieved by taking it up up to the main frames. In used was in areas where the had been busy churning out to an elevated temperature common with Tornado, Prince bolt heads and nuts would be castings, some produced using for a period of time and then of Wales does not have many in the way of other equipment. patterns for components in cooling it slowly. This enables rivets in its frame structure, The frame doubler plates under common with Tornado such the metal microstructure in the the majority of assembly the front of the firebox is just as the cannon boxes for the
46 Model Engineer 18 December 2020 P2 FRAMES roller-bearings. The decision 7 8 was made to ‘wet assemble’ all the frame platework and frame stays. This is common practice in the aviation industry where sophisticated interfay compounds are routinely used in riveted aluminium alloy to inhibit corrosion. After looking at several options, we settled on using red metal primer as the interfay compound, as where it is squeezed out of the The pattern for the locomotive’s rear drag box. joints, it makes an excellent base to ensure adhesion of subsequent layers of paint. The massive casting that resulted! As more stays were fi tted, so too were the footplating, 9 10 hornguides and splashers (yes, the P2 has splashers, albeit small, well-hidden ones!). Many of the frame stays also perform additional functions such as acting as motion or boiler supports and the majority underwent a degree of re-design to best suit the requirements of the modern P2. In addition, it was necessary to add a temporary smokebox The drag box in place, note the Cartazzi frames and the saddle stay to maintain the ‘sandwich’ of three frame plates at the front of these. rigidity of the front of the frames until the fabricated A fabricated, as opposed to cast, frame stay. cylinder block is complete. By the beginning of 2017 the frames were largely complete 11 12 and fi nal alignment could be undertaken. The gaps between the hornblocks were measured and mapped, after which the 16 hornblock liners were fi tted A more fully and their surfaces measured developed CAD with and mapped. The aim was the footplate and to have both liners in each wheels in place. hornblock truly square to the frames and parallel with each other. Individual liners were No. 2007 as it is today, well on the way to completion then to be surface ground the axles were produced in (photo: Daniela Filová). where necessary to achieve South Africa and the crank this, the small amount of axle was assembled at SDRE machine before the same fi rm all four wheelsets which is material removed illustrating and delivered back to DLW then fi tted the tyres which vital for smooth running of the benefi t of having the frame for the Timken roller bearings had been manufactured by the fi nished locomotive. The plates and hornblocks CNC to be fi tted to this and all Ring Rollers in South Africa. wheelsets were fi nish turned (Computer Numerical Control) the other driving axles. This The quartering machine is and sent back to DLW where machined to close tolerances process was considerably a special form of horizontal the cannon boxes could be from the 3D models. At this assisted by the acquisition of borer which can bore crank fi tted to the roller bearings. stage detail parts such as an electric induction bearing pin holes or turn crank pins (if With the frames raised on the steps and sandboxes could be heater which warmed up the already fi tted) from both sides works’ Matterson jacks the added to the frames. During bearings or spacer rings to of the wheelset at the same wheels could be rolled under the rest of the year and into 110 degrees C so that they setting; provided the setting and the frames lowered onto 2018, components for the could be slid onto the bearing is not altered whilst swapping the wheelsets. We had a rolling wheelsets were manufactured. seats on the axle rather than wheelsets. This ensures that chassis at last! The wheels were cast by relying on pressing alone. The the distance between the All photographs are by David William Cook Cast Products axles were then sent to SDRE crank pins and the axle centres Elliott except where stated. and machined at South Devon to have their wheels pressed and the angle between the Railway Engineering (SDRE), on using SDRE’s quartering crank pins is consistent for ME www.model-engineer.co.uk 47 A New GWR PPannierannier PART 26
5 o put the backhead you will be back to the four- which needs to be a ⁄32 inch fittings into context I have jaw chuck and the ¼ inch x 40 union and then the body Doug Tdrawn up the backhead brass rod. Turn down ⅛ inch can be drilled through with a 3 Hewson layout for you (fig 46). long to ⁄16 inch diameter and No. 50 drill. 3 decides The blow down valve for the thread ⁄16 inch x 40 and then The cross passageway that LBSC’s water gauge (see fig 45, last you need a concave tool for the valve can be drilled time) can actually be made with a small radius ground in through with a No. 31 drill and well-known 3 from a commercial ⁄16 inch x the end to form the rounded reamed ⅛ inch and the fittings GWR pannier tank design 40 drain cock although it is shoulders. In fact, if you look are just miniature versions of needs a make-over. worth making the proper little at the photographs of the full the shut off cocks. You now handle for the job. I made mine size one you will see that the need a small hexagonal fitting from a piece of stainless steel corners are rounded off so to attach this to the bottom Continued from p.678 rod tapered to 1 degree and that the viewing face forms of the gauge frame and this is 7 M.E.4652, 20 November 2020 this was silver soldered into a a full circle. I didn’t quite made from ⁄32 inch hexagon 3 small boss in which a square achieve this, but I did get a brass tapped ⁄16 inch for a was filed to fit on the end of fair representation. You can depth of ⅛ inch and then, 9 1 the cock. now part off two of these ⁄16 leaving a gap of ⁄32 inch, the 3 3 However, if you wish to inch long and then hold the ⁄16 upper ⁄16 inch needs to be 5 make the blow downs look inch thread in a tapped bush threaded ⁄32 inch x 40 to screw like the full-size ones then for turning the bottom end into the gauge frame with a
Fig 46
48 Model Engineer 18 December 2020 GWR PANNIER
205 206
Mason’s valve.
Fig 47
Shut-off cock handles. thin lock nut to align it. This of pieces of 20swg or 22swg fi tting could also be used if piano wire. you are using a commercial Now we come to what is drain cock. known as the Mason’s valve, When the shut off cocks which is taken off the left- are open the handle should hand side of a branch off the be vertical with the arm at 45 manifold. The Mason’s valve degrees. To attach the arm is quite simply the steam to the spindle you will need heating valve for that train. four ⅛ inch diameter bushes If you want to make a proper drilled through No. 51. I always job of it, it has a wire wound Fig 48 fi nd it easier to make small handle on it to keep it cool bushes like this from a piece of (well fairly cool!) but I have ¼ inch round unleaded EN1A made this as a dummy as I bar rather than trying to turn didn’t think it would be needed them from a piece of ⅛ inch on an engine of our size. It is diameter. The small handles the shape of this valve which were also turned from ¼ inch is important so I have tried 3 diameter bar down to ⁄32 inch to draw it as authentically as and these were drilled No. 50 possible (fi g 47) so it would be for ⅛ inch depth and also have very nice it you could do the a 1 degree taper (set the top same. Photograph 206 shows slide 1 degree over to turn the this as best as possible. I’ve taper). The two handles and also included a drawing for the the two lower arms are cut whistle valve (fi g 48). from a piece of 18swg steel sheet and the fi rst thing to do ●To be continued. was to silver solder the bushes into some holes and fi le the rest around them (photo 205). The fork joints for the yoke are NEXT TIME from Dave Noble and these are We take a look at the silver soldered on to the ends steam brake valve. www.model-engineer.co.uk 49 1
Geoff Andy Giffen’s 15F at GCMES. (Photo courtesy of Barry Green.) Theasby reports inda Nicholls from to be called the Bolide, I’m in impressed by Basil Wilson’s on the TSMEE writes AGAIN exalted company here! 3½ inch gauge NZR ‘G’ Class latest Lto point out that I have In this issue, a gavel, Garrett and Jim Ellis’s 400 news from the Clubs. confused TSMEE with another scooters, museum saved, day long case clock with club. This time with one in New employment, an E-type, a its ‘astronomical’ aspects. I Zealand. Oh Dear! What can jigger, a fl ight and Stack Talk. also enjoyed the section on I say? I shall don sackcloth I have received from Murray ‘workshop cock-ups’. The and ashes, drink the bitter Lane a copy of his Auckland beautifully fi nished steam tea of General Yen and wash Society of Model Engineers’ gauge, that read backwards; out my keyboard with soap. history and what a book! 400 the axleboxes made in twos I apologise to all TSMEE pages, A4-sized, in colour, on to save metal, too close to be members once more. good paper, bound in card cut apart afterwards; Ho ho, ho, John Collyer wrote to me covers. Hugely illustrated, how we laughed. Well, most regarding my Bolide. He it is a visual feast of lovely of us… The book is full of little built an electric locomotive, mechanisms, especially in the vignettes (are there any other incorporating his calculations absence of physical model sort…?) like, the gavel made on battery power and tractive engineering exhibitions this from scrap mahogany by Phil effort. It will haul six adults on year. This builds on Murray’s Isaacs in 1968, which is still a TE of 16 lbs and has been 50th Anniversary history of in use, and the larger than life running for 18 years without 2009, including a previous member who always stocked problems. Well done, John, short-lived club in the inter-war up at club auctions but never your help is appreciated. By period. Along with the other seemed to make anything… the way, Bugatti’s new car is exquisite models, I was very The Blower, October,from Grimsby & Cleethorpes Model Engineering Society, has Andy 2 Giffen describing in 8 pages how he built his fi rst South African Railways 15F (photo 1). First? Yes, he is building another (!) and a good shot of the work ‘behind the scenes’ which keeps railways running (photo 2) . W. www.gcmes.com Blast Pipe, October, from Hutt Valley & Maidstone Model Engineering Societies, has David Grant-Taylor discussing the chemistry of fuel burning and how the air supporting combustion is changed in the process. The unseen side of track maintenance at GCMES. (Photo courtesy of editor, Neil Chamberlain.) This is part of a larger item
50 Model Engineer 18 December 2020 CLUB NEWS
regarding a change of fuel, i.e. engine which took a little repetitive but has full on-the- SSMEE too! A real vacancy coal to gas. This issue is short time to get right. Using Ivan spot training. No breaks or in this case, member and as editor, Stephen Sandford Law’s book, he managed. A in fact sleep are allowed and printer of Sheffi eld Society had other calls on his time. purist may point out certain applicant must stay glued to of Model & Experimental W. www.hvmes.com matters, but Norman’s the job 24/7, a choice of PVA Engineers’ Steam Whistle, An anonymous missive examples meshed okay so or NMN (No More Nails) for Alistair Lofthouse requires again presents a puzzle, he is happy. John Harris this permanent position is assistance in meeting the with no obvious clue as from discusses making cranks and offered.” See the newsletter demand for his production of which club it is. You need pins. Another contribution by for a full job description… model locomotives. This work a ‘Masthead’ my friends. Andy Bowdidge discussed the The library of recently will be paid for, of course. Famous locomotives of the Hemingway rotary broach, as deceased Len Johnson has W. www.sheffi eldmodel club this time are Flying several members have this been acquired by a local engineers.com Dutchman and Highland Lord, item. Jon Freeman describes bookseller. There are lots and Southampton Society of as fi rst appearing inClub Echo, his experiments on a low-cost lots, all uncatalogued! The Model Engineers, autumn 1945 and 1948 respectively. locomotive. Bob Lilley updates Society has arranged a deal Newsletter, continues Chris There’s also a rather good us on the club locomotive, wherein members can have Harnett’s tales of travelling joke – see the ‘Mosh Pit’* at Brunel, for which most people items from the collection at about the environs of the end. Pam & Ralph have have made parts or had an advantageous terms. Derek Hampshire with his E-type been painting and decorating, input. Wheatley, in the club Gazette road roller, Evelyn. Mention whilst LBSC’s Virginia grows W. www.bristolmodel of 2010, fi lls us in on Oliver of this mode of transport steadily. Ted Joliffe made a engineers.co.uk Bulleid’s 'Leader' locomotive. caused some confusion, handy square for the ‘rough The Newcomen Society That would have been a with colleagues wondering jobs’ he wouldn’t go near with advises me that Engineering great exhibit at a preserved if it was a Jaguar or a Rolls- his ‘Sunday Best’ equipment. Heritage Australia magazine line today. (For more details, Royce. Either way, they grossly He used a piece of holly is now available. Headlined is see Kevin Richardson’s infl ated his estimated salary. from a branch removed in the former Tramways Power Leader, Steam’s Last Chance, Catherine O’Shea writes of gardening and it is as pleasant Station Museum in Ultimo, Published by Alan Sutton – her son, Connor, wanting to work as people say. The Sydney, which has been saved Geoff.) Mike Joseph begins a an electric locomotive he next newsletter clears up the from closure and demolition. series on ‘My favourite tool’, could drive himself. One matter; Chingford & District EHA magazine is free, from his being a Stanley fl at-bladed was obtained, but he had Society of Model Engineers EHA@engineersaustralia. screwdriver, 50 years in his to disassemble and paint it it is. The October issue said org.au possession. (A relative was himself. Happily, he needed Mr. Turpin (W.A.?) showed his John Townsend writes a sniper in WWI, a speedway very little assistance. Roger new locomotive, Hybrid. Ted to say that in the rear page rider and Bentley mechanic Lunn, admitting to being Joliffe modifi ed a pipe and machinery advert of M.E. 4649, in those cars’ heyday. He an absolute novice, thanks rod vice, originally made by the Morgan Rushworth box was banned from all funfair members for being so helpful Footprint and designs one for and pan folder is supplied with shooting galleries because he when his B1 broke whilst being others to make, replacing the spare fi ngers. How thoughtful always won!) A mystery object prepared for a boiler test. This industrial-type parts in favour (if gory)! is a diagram of some sort is only one benefi t of being a of components easier to make Centurion Smokebox, from of steering gear, but what? member of a club. One day, he in the home workshop. Centurion Society of Model (I think, with my off-the-wall may be in a position to help W. www.chingfordmodel Engineers, has details of psyche, that it is of a heavy another novice in his turn. engineering.com Hannes Paling’s SAR 18E bomber from WWII. It looks W. www.southamptonsme.org The Bristol Model Engineer, electric locomotive under reminiscent of a the ‘works’ PEEMS Newsletter, autumn, from Bristol Society construction. Also a picture of below a Lancaster control September-October, from of Model & Experimental a sort of rail-mounted ‘Pedalo’ column, seen from inside the Pickering Experimental Engineering begins with a (photo 3), the origins of which bomb bay – Geoff.) Engineers & Model Society, photograph of a Homburg- can not be identifi ed, despite W. www.stalbansmes.com admits that there is nothing hatted gent riding a motorised two ‘reverse image’ searches. scooter. The date? 1919! Not If readers can help to identify electric though. And, didn’t the photographer, I shall be 3 some parachutists use little happy to acknowledge. powered scooters in WWII? W. www.centuriontrains.com Various Zoom virtual meetings St Albans Model saw Andy Bowdidge describe Engineering Society is the maintenance and repair reacting to the present of the catenary on electrifi ed lockdown conditions by rail routes. The pantograph providing a little employment. is monitored by CCTV in real Secretary, Roy Verden has two time and can spot potential vacancies for those of smaller problems early. As a ‘dewire’ stature. He says, “Must be is estimated to cost about to 1:33 scale but would £2m per incident, it is a worthy consider a tall 1:35 scale tool. Norman Rogers made person(s) with long trousers. bevel gears for his Durham Not suitable for ex-military or & North Yorkshire traction heroic personnel. The job is A modern rail inspection trolley, or ‘jigger’. (Photo courtesy of Mr. Nobody.) >> www.model-engineer.co.uk 51 much to report. So says of lapping surfaces. Peter 5 one Jonathan. I usually Bramley reports on lathes find something interesting he has owned and modified, in almost every newsletter starting with a Super Adept. crossing my doormat, so Now, a Red Letter Day! Ivan we shall see. Firstly, the Shaw’s Personal Aircraft has Society has been given three made its first flight! It was models, made by the donor’s photographed by a spectator father many years ago. All and the camerawork is a little mostly completed, a draw shaky, but it was recorded for was held and three members posterity, which is more than were lucky. Then, like buses, was the case with K5054 ** another similar bequest, of See https://www.youtube. tools this time and again a com/watch?v=ERcrOm_we3M draw was held, in which one At Elvington, Jason Liversidge of the beneficiaries of the first set a new record for electric draw was lucky again. Time wheelchairs, 60 mph! Jason is for him to buy a lottery ticket, very disabled, can not speak Tor’s own unique locomotive also at BCSME. (Photo courtesy of Paul Ohannesian.) methinks. (I never get this and can only move one hand. sort of thing, but then, I’m not I think he may be a second drive system, reminiscent of the steam blast leaving a at my bequest at this time Lewis Hamilton! Exceptionally those used on Snow Cats, but locomotive chimney has been of day – Geoff.) A donation Well Done, Jason. Now then, driving inside wheels (photo described as ‘stack talk’, which to the Red Cross was made Jonathan, what were you 5). Ingenious! Chuck Laws was thought very descriptive. in thanks. Chris Bramley saying about there not being explains the different sorts Editor, Trevor Combes, points recommended the use of Cleco much to report? of batteries you can get for out that Robinson 9Js were fasteners. I had not heard W. www.peems.co.uk your watch, calipers, camera known as Pom-Poms from of them, but seeing them in British Columbia Society etc., which, as editor, Paul their exhaust beat, after the use brings back memories of of Model Engineers sends Ohannesian says, should be rapid-fire anti-aircraft gun aircraft looking like trainee The Whistle, October, in two followed up by reading this batteries onboard WWII ships. porcupines in the factory, now parts; the pandemic and its item, which is 9 pages long, A large number of items were I know what they are. David aftermath; and the normal on the same subject. https:// revealed at the increasingly Hampshire built an OcCre transactions of the society. www.lr44batteryequivalents. popular Zoom meetings, The tram kit and modified it to run Part 1 revealed this great com Paul has achieved ‘Show & Tell’ aspect of which on his garden railway. With photo of how they dealt with another success too, in that a is always welcomed. Further over 600 parts, his ‘Lockdown’ the problem… (photo 4). Part picture of his Phoenix appeared information on the milk project’, ‘LCC 106’ has taken the second has young Tor’s in Live Steam, Nov/Dec 2020. tankers mentioned recently, is him six months. Paul Gammon self-designed locomotive, W. www.bcsme.org that the tanks were inclined writes on the importance incorporating a novel chain Northern Districts Model so the last of the contents Engineering Society (Perth) would drain out under gravity. Newsletter, November/ Anyone embarking on a tanker 4 December, says that over 50 of their own should bear in past and present members mind that although the tank attended ‘The Reunion we had slopes, the lettering on it does to have’ in August. The large not! Martin Harrold describes skip acting as Gate Guardian the club’s four shed clocks, has been removed, saving a which, to avoid scrambling four-figure sum and has been around on the pitched slate replaced by individual bins for roofs, take their time from recyclable waste. The Garden passing satellites, using the Railway Open Day attracted GPS system. 18 locomotives; more, in fact, W. www.gmes.org.uk than members present… The And finally, Nelson was steam clock in Vancouver is only 5 feet tall, his statue in described by Paul James. I Trafalgar Square is 15 feet tall. think I mentioned this clock That’s Horatio of 3:1 some time ago (Yes! M.E. 4531, under MEE, Auckland). The * You should be pleased I Cromford & High Peak Railway didn’t call it the first thing that is described by Bill Walker, came to mind when referring Buxton shedmaster, who had a to a pile of old detritus… footplate pass. ** The Spitfire’s first flight. W. www.ndmes.org.au Guildford Model Engineering Society’s GMES News, Contact: September, begins with [email protected] A ‘masked up’ locomotive at BCSME. (Photo courtesy of editor, Paul Ohannesian.) the claim that the noise of
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