FREE a =IVIODEL CNS: : =a Vol. 202 No. 4349 8 - 23 April 2009 96 [AUS $8.95 | N2SIO.80 BUILDING AN AWARD WINNING GWR BULLDOG LOCOMOTIVE AN ENGINE DRIVER’S STORIES i FOR THE BURRELL 6in. SCALE Te. GOLD MEDAL (Kz TRACTOR Qean UAE LC es Dae LU aera ened rye consron Ircuahg acest 3 ec na oyna ac th ‘Seta pt aba Armortek at Kit Price £1,953.00+PaP ov (MotoraEloctonica and epecil fac ae optional xvas) proud to present the Panzer Ill ference ron EA eam Se lgecom aD) 1/6th Scale All Metal tare linia are mals The Panzer Il offers a fully ee ene oe er re es ee eee ‘quality components Peterhead eed a ee eke Ce ee ee ‘easier to handle and transport. you do not yet own an Armortek pee a ee tee ese eee er eee eases STS nae ed Se eat eee et cae) e-mail: [email protected] | Telephone: +44 (0) 1404 892956 _Atvinees uring on see bat beat ‘Mevnaner yen neuarg weanianen Ths tion re anc sin br ni ee ee ee eta will be machine engraved with the serial number and the Armortek Se ee ee a eee ees eters! Se eo eed See a ore ee en te eee tee enn cher cast alloys and materials, We use no GRP. The model features ‘scale armour thickness and genuine working torsion bar suspension ee ec developed in the 1980s by Germany and used extensively in World eee ee ce eee) Cree a ee ey Pare eee aetna ‘The Panzer Il was used in the campaigns against Poland, France, Pee aeons oe) =)MODEL ENGINEER blah by MobyStore Ltd rk Bhonghon Ken BAS Gel Kral: custome igs. com "44 (0)eas a2 2062 warwimphoobyetoreccem ‘SUBSCRIPTIONS UK - News Rena ana “eis O8ase 777 807, ral: modeengneerduacpon oo. SA & Canaca subscriptons ‘New Revs ana Engares Tot (008) 732424 7011 st of Weld aubsortions Now, Ronevale and Encaies “eb 944 oytese 483814 BACK ISSUES & BINDERS. Tok: +44 (0)844 648 8820 ma cublarmesewmenerynbeyterecorn EDITORIAL, Ealtor: David Clark. “Tel 444 (oyt047 821198 nal cn ctrhorrabbystore cam Production Eeitor: Ken Barber PRODUCTION Designer: Wort Masson tustrators Gshame Chambers 'Pre-Prese: Bran Visors Production Manager: Fihard Baldwin ‘Ad Production: Fobh Gray ADVERTISING Senior Sales Executive: Duncan Amatng Ema duncan [email protected] “ot 084 8 8238 MARKETING & SUBSCRIPTIONS “Marketing Executive: Heather Morison MANAGEMENT Head of Design and Production: Nii Cottey ‘Special Projects Publisher: Niki Parker’ Subscriptions Director: Rsbocca Bighion ‘Chief Executive: Onen Davies (Chairman: Pater avin t (a) mytiobbystore (© NyHobyStore Li, 2000 ‘Aah econ ISSN 0008-7025 sod opine A emcrebcat bien be pep "Ja rinpue arn ba baker cao oun mporane er ots th mages cBrtnyeshonons ung tan ach ars oo ‘etn sar nsiwron low Dh are re war the tn tage Model Engineer 8 Aprii 2009 IN THIS ISSUE Vol. 202 No. 4349 8 - 23 April 2009 431 SMOKE RINGS ‘News, views and comment on the world of model engineerin. 432 POST BAG Letters to the eaitor. 436 TRACTION ENGINE LAMPS Tony Meek makes 3in. scale lamps for his traction engine. 440 STEAM ENGINES RETURN TO STOCKTON-ON-TEES Graham Tebbs reintroduces model ‘engineering into a school with a simple oscillating engine and boiler. 442 AN ENGINE DRIVER'S STORIES Tales of a locomotive man as he progresses from a cleaner through Various disciplines to become 2 locomotive driver. 444 EMPIRE BUILDING Allan Crossfield tums an abandoned locomotive chassis into a Gold Medal Winning Bulldog locomotive. 448 THE RE-CYCLE ENGINE Dave Fenner starts the cylinder assembly and looks at the main reciprocating parts. 452 CONSTRUCTING BRITISH RAIL Mk. 2F COACHES Ken Toone makes a rake of gauge 4 coaches to run behind his British Rall Class 86 locomotive. 456 KEITH'S COLUMN Keith describes the springs for Lifan, bis 71/4in, nartow gauge locomotive, 459 ROAD STEAM HALF-SCALE BURRELL GOLD MEDAL TRACTOR Martin Wallis looks at patter ‘making forthe cylinder of his new Gold Medal traction engine. 462 EDWARDIAN ELEGANCE THE PHOENIX MOTORCAR Ron sted looks at the Phoenix ‘motor car from the Edwardian era. 468 DIARY Forthcoming events. 469 NEXT ISSUE FHighlignts of our next issue's contents. ON THE COVER... ‘Dove Berman's superb haste Burl Gold Medal actor was on show at the Wnisendine 42312 & 24V MOTORS AND SPEED CONTROLLERS SPROCKETS AND CHAIN . GEARS SPEEDO'S . AMMETERS . BATTERY CHARGERS PNEUMATICS INCLUDING VACUUM/PRESSURE PUMP BATTERY CARE PRODUCTS « SPRINGS « BEARINGS WHEEL BLANKS . SIGNALS . FUSES -LED’S SWITCHES ‘TEL:0870 9089373 (national at) FAN:01282613687 EMAIL: pselcctonies@bvinternetcom FOR YOUR FREE LIST PARKSIDE RAILWAYS UNIT 20 & 34, VALLEY MILLS, SOUTHFIELD ST. NELSON. LANCS. BB9 OLD Visit the Stand at the National Model Engineering and Modelling Exhibition. Harrogate 8th, 9th & 10th May 2009 ina een (Sm » 220mm nemo 2 ado fintlas stp Teese ater cation or teal at es ape os 20 [009m rg bah, Phoonix Precision Paints Lid PO Bb 8238, CHELMSFORD, Essex CM! TWY- Ta (1268) 720540 ecg stn fab ee) Seren MAXITRAK.CO.UK Pere l ey ee er gfe td Poe a ae er CT aie aX scanned lings to CAI eee TRIAL Fulkworking evaluation! 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CATALOGUE - £5.00 80 PAGE FULL COLOUR Please send £5.00 for our eighty page comprehensive full colour catalogue which covers our entire range of models and acces Stuart MopeELs oO) ee 1 AD, VALE, G EY, UK, GY SE UCIT etree ener& WESSin ween kee 16th and 17th May 2009 (10am to 5pm) St Nicholas School, tham, Surrey 16mm layouts, G scale, 7¥4 narrow gauge miniature railway. + Model boats, Toyshop steam, Bayko 75, Dollshouses, Preservation societies. +Trade stands, plus the renowned member's sales stand, Merstham Model Steam Show NEW CHESTER SHOW; jeeMs NEAR LONDON Tel 01708 523916 Open: Monday ~ Friday 8.30am ~ 5.00pm & ‘Saturday till Noon (Aso stoks of Used Lathes, Mis, ec) Please check our website: EMO AWoule PO) oa ‘Over 70 challenging projects ee ee Ceasar a © Work Holding and Positioning © ‘oo! 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K oam (07860 858717 Send 6 first class stamps for catalogue & Price List pm SATURDAY 42.00 noonSPECIAL OFFER SPECIAL OFFER astimr “Soleveebeanay hanes ne ont |= | Al “Pegeontonor aypraon tp Asati go sways ‘Linge anes no gh et J ‘ocak 1,250.00; ‘rie Incudes UK Maman aetivery ana vAT “Soednare te IE Ne actaniss ues Iitad aatvory Sorat caumn craves poswe macs aeaon nn GTN ke a lonctinde sepotesen apart maine Wud FREE of charge ie Gostoidouny“heveaelerer witheach Whtia mle LIMITED SPECIAL OFFERS Setot 4 colts, DHS ie Mota casing 67180mm Pence UN alland deter and AT pete cna oe a Oa SPECIAL amon Z ie = 4/100 _|startess toot = 375mm ie line (08d ova ore hoon 67/150mm, Large, 025) to road sor tem Na 2850 hem, 7088 me Pus C250 pst and pring -Sagmertad ne = anerraoure eee with 0, FISHER LANE, CHIDDINGFOLD, SURREY GU8 4TD_ 1428 682929 [email protected]Galiper- 100mm © Worth £24.99 CMO) U ellinygcieelia) eschs(cl=lMirclaalt PKG eA -V aaa U mn cialg ¢0.01mm graduation ¢ True mm/inchiconversion EM Melediaeasat sla DIGITAL CALIPER OPERATING INSTRUCTION Goede eer FREE GIFT UK ONL) [C11 would lke to subscribe to Model Engineer paying £17.88 every ‘3 months by Direct Debit {I woul tke to subscribe to Mode! Engineer for 1 year (28 issues) with a ‘one-of payment: ClEurope (rire) £78.00 CROW Alrmal £35.00 Insrutlons to your bank of bulingsocaly to pay by Dect Deb. gown Ongmnators wlerence 42250207 PY Wess ame of bani ‘Adreee of bank Postcode ‘Account holder Signature Date Son eae T sccount ruber Te mt Reference Number (Official use only) {| | | T | | | | Instructions to your bank or bul [ra anon tasa catad rato esos al awl posad steal yb ey Pas ay Vir Lt renaon apo beepers sz yh ran wt My i Mente ive Me, Int Surname Aarons Posoode Country Wa Webi, TEs & conomONS. Ot ens 24m fo 2, free GR UK ny Sens Den ‘ra veri pros rican nwa | EB Grrtat by Geral Stephane | a (prc ao NOT wa eb cet vaca crore ret proaucl ct ros poseSw] A tale of two traction engines Peter Southworth has pointed out thatthe Correct photo ofthe Alehin made by Lesney was not printed (A. 14348, ZT March 2009). ‘The correct one is below, Editorial reorganisation Following an editorial restructuring and improved working methods, Modo! Engineer will be edited by me, \\ David Clark and the existing Production Eator, Kelvin Barber. This will not affect the quality of content currently appearing in ‘Model Engineer. ‘Subscription delivery problems Mode! Engineer issue 4348 was delivered on time to UK addresses and overseas deliveries, at least to Europe, have improved beyond recognition. Most UK subscribers received their copy on the Saturday prior to the on sale date. France ‘and Ireland at least, received their copies on the Monday, ‘an improvement of almost two weeks. We hope to continue this excellent service. New Speci Eitiod magnaine |/am working on another special ‘magazine that should be on sale in early May. Itis about ‘model engineers and their workshops. The main featured atticle Is 100 years of SMEE workshops and a visit to the current workshops of SMEE Headquarters at Marshall House. (Apparently, there are three different workshops in Marsal! House.) The SMEE article Is boing written by Mike Chiisp. Also. featured, in no particular order, are the workshops of Ashiey Best, Dr. Peter Clark, Stuart Walker, Charlie Stone, Mike Sayers, Roger Castle Smith, Harold Hall, and several other ‘Mode! Engineer contributors. More details should be available in the next issue ‘and we should have a phone number for you to pre-order your copy. You will also be able to order through our website wwwamyhobbystore.com Narrow Gauge Special The 16mm Narrow gauge in ‘your garden magazine Is selling like Not cakes but you should be able to get a copy through WHSmith or through our Model Engineer 8 Apri 2009 customer services, T0844 8488822 Moni 10am till 2pm. Unfortunately it is not available in every branch (of WHSmith, but if you can't ‘see It n the rallway section or rear the model engineering ‘magazines, usually down on the bottom shelf, try looking at the: men's interest section on the top shelf. It has been spotted there in the Bath WHSmith store. | sometimes wonder IEWHSmith thinks rallway ‘modellers and model engineers are 3ft. high dwarfs! ‘Along round trip {lam off to Poole for Easter week which will be a working holiday am hoping to vist the Bournemouth DSME track at Littledown on Bank Holiday Monday momring with a tip ‘to Swanage Railway in the afternoon, Tuesday wll be going to Seaton to visit the {vamnay and also to visit the Toolbox at Colyton. Wednesday | am traveling up to Nottingham to visit Poly Engineering and | am going to the Myford Open Day on Thursday. Friday morning | am visiting Are Euro Trade and then driving down to visit Tory Webster who has mitten a sees of articles cn building a portable engine. Next on the lists a visit to the Leighton Buzzard Narrow Gauge Raliway on Fiday afternoon ‘Saturday | am going to the South Wester Model Engineering Exhibition at Shepton Malet and finaly on Suncay, hope to stop off atthe large Scale Ral Exhiton in the Midlands on the way home. you ‘900 me at ary ofthe exhibitions ‘oF the Myford Open Day, feel free to come and say helo Locomotive rallies had a phone call from ‘someone who mentioned that there used to be a Martin Evans Rally and also a Don Young Rally. Do these two events stil exist? Are there similar events that need to be publicised? Please let me know. Diary and News Diary is now back up to a page {as events at this time of year are more numerous. However, the News is missing from this Issue. Hopefully we will have plenty of news for the next Issue. Please emall me news {rom your local club together with a relevant photo. Faulty locomotives - caveat emptor “Thank you for publishing ‘Sutton MEC’s warning about boiler certificates in News (ME. 14342, 2 January 2009). This piece also appeared in the Southern Federation Newsletter land subsequent to that | was contacted by the Secretary of Stalnes SME. It seems that Sutton’s experience is not unique; Staines had two further examples of dealers selling locomotives with suspect boiler certificates. The dealers, al In the SE of England varied between the clubs; however the independent non-club boiler Inspector was common to three of the cases, ‘The worrying aspect about the Sutton and Staines examples is that the buyers Involved were all novices with limited factities and experience. Correcting the boiler faults to obtain @ Southern Federation certificate will involve a good deal of work and further costs. Having had their fingers badly burned, will they remain within mode! engineering? One Sutton ‘member has already given up ocomotives and sold his model at a substantial loss. If ary readers of Mode! Engineer have similar examples of this practise please contact, ‘me via Sutton's Hor-Secretary, Bob Wood 0208641 6258. This Will give us an indication of how Widespread this deceit is within ‘model engineering”. Paul Harding Boiler inspector SMEC. Coffee break idea David Scott has emailed a ‘suggestion thought up by him ‘and his mates. “Ying's Coffee (Cup Engine gave us all an idea ‘to make one each so when the engine stopped, our coffee or teas would be the right temperature to drink!” Has anyone tried this, I wonder if the coffee would be too cold? 431Taper Turning, a correction Sources for rolling stock a replacement old French SIRS, -Imust make clearto In response to Mr. Tiewinnara's lock spring from about 1777 ‘il your readers that the taper letter Postbag (MLE. 4345, 13 Perhaps readers can suggest setting jig refered to in my February 2009) may I suggest another grade of steel that article Producing sallow the following: would be suitable? \ tapors (ME. 4346,27 1) Take a look at Dou 8. Rawlings, Orpington. February 2009) isnot my _-Hewsen's website where you design but that of Mi Will fnd an online catalogue Black Five help 1 POSTBAG Tumoull thought Ina ——_containing, nat eniy many SIRS, lan Parsons raisos the made tis quite clear at_ Individual tems for use in ‘problem of brake hangers least twice in the body of wagon construction, but also on Martin Evans’ Black the article but somehow a a number of sets of wagon Five (ME. 4347, 13 March mistake has been made at _ drawings for various wagons. 2009), Having checked the Model Engineer by attibuting 2) TEE Publishing also sell a dimensions and redrawn at the design to me. Mr Turnbull” couple of sets of articles fullsize there appears to has designed an excellent written by Doug in booklet be sufficient clearance as piece of equipment and righty form covering an LMS Brake orginally drawn. | have also serves ful creat for his Van and a 16ton Steel today seen an exampe of the efforts, Ihave simply tied to Mineral wagon. These books Highlander where the motion advise readers how to use ‘ve a very good idea ofthe plate Is correcty fhe at the auge blocks to sot up the ig. construction methods used, _S%in, position. Yes there was Eric Clark, by email. not ony for the wagons. interference in that case but CLASS eserbed but alo for mary this has occurred because ‘eas my fait, not Eres, ther wagons. the builder failed to cut away, my apologies, Ed. 3) If Shaun can find a ‘back: ‘the lower rearward section of copy’ index for Engineering nthe motion plate mounting Wagons in Sin. gauge Miniatir he should be able face in accordance with the SIRS, I'm pretty sure your to frida numbor of ether drawings on sheet 6, Perhaps readership In Wales, or other ticles by Dou covering the the trouble Is that the castings railway historians for that construction of other wagons are universal, ie. not handed matter, will know the answer as well whereas thelr intended use tomy question about the tank 4) Shaun may also tke to look Is handed, although inthis locomotives that ran on the atthe GLEMLA website for particular case the builder Rrymney Raitway. further information on Sin. nag made a bull up mation The Reeves 2000 set of s2uge ground level Railways. plate from steel but notin drawings fora Sin. gauge in general accordance with the drawings! ‘model show the tank engine David Harts, by emall Ken Willson, by email. with tender. Also ve seen a photograph showing the Source of spring steel? _—_Black Five help 2 engine heading train, the SIRS, -Could you please help SIRS, -n response to the frst passenger coach of which me find someone who can request for help frm fan Write to us was coupled directiy to the ‘supply a small piece of EN45 Parsons in Postbag. | too font engine. The end ofthis specially or ENA7 spring steel orits discovered the probier with ‘ousrotte assured designed! coach presumably equivalent? lam desperate _the leading brake hangers on Sipeneeneees contained a coal bunker? | want as the original spring was ‘Martin Evans’ Highlander 7¥%in. ire carr cet onsouosct | to confirm or otherwice that both lost when sent away fora gauge Black Five. My cylinders Serene ore these versions are authentic. replacement to be made. and motion brackets were seid be sat to John Rhys Goymour, Knysna simall fat plece 4 x 1% x already installed as per the Treeaton, ‘SME, South Africa. lin, would be okay. It is for dimensions on the drawings Inala, but@lite reshaping of the tins a fonts ofthe hangers alow the Sonor me, Wolf Power tools leading brake blocks to ft to noe SIRS, - Re. the query about Wolf Tools in Postbag (M.E. 4346, the wheels as required. The Cen cas 27 February 2009), & rambling discussion of the history of Wolf | reshaped hangers are hardly fotesuon aie con Tools appears (of al places) onthe Australian Woodworking | visible ance the valve gear Is a Forum site at: assembled. | am well on with Sess Itpi//www.woodworkforums.com/archive/index.php/t14867.htmi | the project but after 44 years Shesosea ote The best response Is one from someane called Gerhard. bul time, the energy 1 once nocimmaencas na ascume you cant reproduce Gerhards account, fr copyright | hadis now lacking and to. tora ao ann ea reasons, but urless someone has beter information, you might | manfandle the model toa local Spee wok ate ass the reference onto your corespondent Johan Berserk. The | track is not something I relish fons, short answer appears to be that Wolf was purchased by Kango. | itil make a nice display piece Corespordets’ datas ae Tools Lid of Peterborough inthe early 1980s and graduallylost its_| in the lounge witha drip tray el used nls oe separate ideny ina seres of tokeovers and product changes. | underneath! Meo oert en John Keane, by email On a diferent note, may we ere tonerdnd eoprept. be tole by Dous Hewson what is 432 Model Engineer s aprii 2009Inferred by his reference to the ‘Springbok’ design? (Postbag, ‘same issue). Chris Abbott, Leicestershire. Stuck after winter 'SIRS,- When storing my locomotive over the winter, drain my water lines and allow them to dry. When spring ‘comes, many of my check valves are stuck; they require taking apart or 2 tap with a hammer. ‘am curious to know what others do to prevent this problem. Steven Getz, Malvern, Pennsylvania Clayton in 2in. scale SIRS, - Can anybody recognise from these photographs the 2in, Clayton that I purchased from MJ Engineering last autumn. The workmanship Is excellent and a great deal of the model is complete, including the brake system designed by Mr. B. J. Lundberg. The engine Is almost fished except for the valve gear. Ibis here that my quest begins, Robin Dyers original design Used Joy's valve gear, but in June and later in July 1988 Mr. B. J. Lundberg wrote in ME. about his achievement in successfully reproducing the engine with the valve gear as in the fullsize engine (this may have been called ‘Allen vale gear’). He drove a countershaft Carrying the eccentrics by means of a pair of spur gears, \which meant that this rotated in the opposite direction to the crankshaft, making timing ‘somewhat tedious, This Model Engineer 8 api 2009 Introduced another problem In that the crankcase had to ‘be modified to accommodate the arrangement. Mr. Lundberg, commented at the time “it was a squeeze getting Ital in. My unknown builder impreved this design by adding a jockey ‘spur whee! betwoen the two main wheels and altering the juxtaposition of the two ‘eccentrics and their respective valve rods. He must have done ‘some detalled drawings, but sadly they did not come with the engine. He had only made the two eccentries with their rectangular holes, and that was, here | picked up the trail have successfully drawn ‘and made the countershaft after many attempts. Today the engine has run well on ‘compressed ait, though it does need a bit of refinement in the light of knowledge gained The boiler again shows distinctive signs of my bullders attempt to falthfully reproduce scale size fittings. The photo of the boiler clearly shows the regulator and the safety valve. The latter has a double release arrangement, placed vertically Instead of horizontally, as is the ‘more usual practice. Mi Engineering wos, Understandably eluctant to reveal the identity of the builder or the vendor, but | hope that without causing any problem, ‘somebody can throw some light on the origin of this very Interesting model. Al replies via the Eaitor please. Archie Came, South West Scotland. POSTBAG Gutter materials! ‘SIRS, | think | have found a new source of material. Most cays I walk into town and I keep an eye out for bits of metal in the utter. Its surprising what you find. | now have a gardener’s Seed tray overflowing with screws and bolts up to 1in. diameter. leven found a 10in. length of %sin. diameter non-magnetic stainless steel bar. | worry about the state of some vehicles after my new found bits have fallen off them! needed a really large hexagonal nut with a small thread to complete my ‘Simple ball turning attachment’ (designed by Steve Papworth, ME. 18 June 1993) and it was a simple ‘matter to cut the head off a large bolt (probably about in. dlameten and face both sides. Then the piece was drilled and tapped for the thread. And all for fre. ‘Avoid bolts that have broken due to fatigue cracks. These are the failures that have a smoath concave or convex surface. There ‘may be the start of another crack in the bit you want to use. ‘You can also find the lead balance weights used on motor car Wheel rims. I now have enough of these to carry out my plan. This is to meit them down (presumably the steel clips wil se to the surface and can be skimmed off) and then fil the inside of a large car engine piston complete with gudgeon pin. This will then make a handy anvil forthe bench top, | have yet to find @ ‘suitable piston in the gutter but you never know what will turn up. ‘Nol! Heppenstall, Cheshire, Tide clock Waterproof tanks SIRS, - found Roger Castle. SIRS, -Inote that your ‘Smith's article on tide correspondent Gerry Brough predictors very interesting (ME 4346, 27 February 2009) (ME, 4347, 13 March 2009). asks for information on building There is one thing I've always locomotive side tanks. My wondered about, why, when article on building the Guinness, the earth rotates once per Engine (ME, 25 February day, do we get two more or 2000) refers very briefly to the less equal tides? Perhaps Mr. use of plates of brass screwed CastieSmith or some other or riveted to brass angle and knowledgeable chap could the tanks made watertight with enlighten us? bitumen paint poured inside, Duncan Webster, by email ‘willed around then drained. This technique avoids the K.N. Harris distortion which might be SIRS, - In his book Moder caused by soldering. | used Stationary and Marine Engines 6BA countersunk screws which page 66 In the 2000 reprint, were filed and flatted down KN, Harris gives brief details before painting. The Guinness ‘ofa 3in. scale launch engine locomotive was finished in he built which won various 41995 and the tanks were awards at the 1959/60 still watertight when I had to ‘Mode! Engineer Exhibition. dispose of the engine in 2002. ‘The drawings for this engine Norman Smith, by email. \were available (in 1964) from Greenly Engineering Models. New valve gear simulations Can any readers let me know it SIRS, - Charlle Dockstader some other model engineering has just added three new ‘company took over the supply programs to his range of Cf these drawings and if anyone valve gear simulations. Model has copy of them available engineers are increasingly ‘on lean for photocopying? | turning to ICT when they need Would be more than willing to. new solutions to old problems make a contribution to their _—_and these new simulations entertainment fund for that _—_will be of particular interest privilege. to those modelling British 3. M. Helliwell, by email, prototypes. Hitherto Charlie >> 433Dockstader only provided two forms of Stephenson Valve gear simulations which followed the commonly used ‘19th Century American arrangement where the die block drives a rocker directly Many frst time users of the software were put off by having to assign certain values to the various data fields to eliminate the rocker and even then the program would not accept a commonly Used British arrangement of ‘Stephenson Valve Gear where the weighshaft is located below the centre line of the ‘motion. ‘Stephenson British Outside ‘Admission (Abbreviated to ‘StephBrt for the fle name on the computer) permits us to Investigate the familiar form of Stephenson gear and get accurate information about valve events from a wide range of British built locomotives hich used this arrangement of valve gear and should help dismiss many of the misleading cold myths and legends ‘surrounding this valve gear. ‘Simultaneously Charlle has also written two versions. (of a program which will provide a simulation of the Great Western Railway's arrangement of Stephenson's Valve Gear as applied to 2eylinder piston valve locomotives from the time of 6. J. Churchward. Almost every one of these famous prototypes has been described In the model engineering press over the years and opinions have often ditered over the ideal proportions of the various components of this valve gear, particularly When outside admission (slide valve) versions wore described. The late Professor Bill Hall's programs have provided a lot of new information to all who have taken a close interest in these matters over the past 20 years but there were various aspects of this software which either curtailed investigations. ‘or omitted components entirely. Charlle Dockstader's ew programs ‘StephGWRin’ and ‘Steph@WRout’ will allow 434 2 very fll investigation of the valve events produced by this arrangement of Stephenson Valve gear as it permits Independent variations of the angle of each eccentric and, the length of each eccentric rod and it even includes. the link block hanger, a ‘component omitted from other simulators. The software is available 28 ‘freeware’ from Charlie Dockstader’s website wor. tesn.com/charlled/ lam sure that even those ‘model engineers who eschew ‘computers and everything connected with them wil join with the rest of us in thanking Charlie particulary for this new Software and forall his work on behalf of our hobby. ‘Simon Bowditch, by email. A complete novice SIRS, - For some of the readers’ who may be struggling with a project, | offer a few words of advice. The word novice in the Oxfora Dictionary has two meanings; 41) A beginner, which is fair ‘enough as that is what | am, 8 complete beginner. 2) A person preparing to be ‘a Monk or Nun. The latter \'m afrald will never happen ‘or the air in ry workshop can become quite biue at ‘tees. I'm sure that an ‘experienced engineer could Probably make another locomotive from the rejected castings and parts Ihave ‘thrown away into my sorap bin. 'm tying hard to tearn ‘rom my mistakes but it's so frustrating at times. Perhaps {1am trying to run before 1 can walk as the saying goes. 1'm over 50 and have had no engineering background and there ties the problem | think. lve had no apprenticeship to learn the basic skils. | read somewhere that because we ‘aan buy cheap imported tools we tend not to make them any ‘more, unlike the past where the ‘same tools would have had to bbe made because of cost and so the basic skills would have been gained; only then would We have started a project like @ steam locomotive, lead somewhere else that alarge percentage of projects ever get fnished, now | know ‘wn! In hindsight | would have approacted the hobby na different way, made something simple and gained sore ‘experiance but I chose the Kin. gauge Atlantic Ayesha that was being serialised in ‘Model Engineer because | was told it was @ good beginners" locomotive and they were right, itis (photo above). | started well enough until I came to the liners. With al that precision tuming my nerves were getting more and more frayed. So decided to shelve the eylinders fora while before | made a ‘mess of them and have a go at the tender This was the right move for me, | really enjoyed ‘making it and 'm pleased with the end resut. It also gave me the encouragement to continue with the locomotive row that the tender is complete (photo above). (On the other hand, when it does go right like the axe pump | hhad been working on for the past few days actually pumped water, well only & noice can feel the ‘way do and when I go bursting into the house lite some maniac, shouting its working, its working ‘come see, come see and my partner makes the sympathetic noises she normally does and tells me how clever Iam, well It rakes it all worthutile doesn’t | Now then whats next, oh yes, back to the oytinders, right then here we go then.. Steve Tertls, Stoke on Trent. Second-hand machine tools SIRS, - Regarding Michael Green's Postbag letter ME. 4344, January 30 2009, Firstly | would like to say that {was In no way offended by Michael's earlier letter (ME. 4340, 5 December 2008) and am rather flattered that he took my advice and is now ‘shaping up’. Lots ty to answer his {question “What do we look for?" In order not to get carried away | will stick to lathes of the 3.5 to 6In. centre height range. | would be looking at two main criteria: Specifications and Ergonomics. Specifications: As already mentioned a ood tip Is the centre height (C/H) to bed width ratio where the bed width should be approximately 1.5 times greater than the C/H. ‘Another tem worth looking at is the headstock spindle bore. Ona 3.5in, lathe it Model Engineer 8 apni 2009should be 20mm or more, 20 to 25mm or $0 on a din, 25mm to 30mm on a Sinch ‘and 30mm plus on a 6in. lathe, There is not much point hhaving a chuck with a back plate bored to the same as the ‘chuck body and being unable to pass reasonable size bars through the headstock. Also Important is that a good-sized spindle bore will have larger headstock bearings, the bigger the better as far as | am concerned. | would be looking, for good quality taper rollers at both ends of the headstock, with larger bearings at the cchuck end. Speed changing should be ‘easy and quick. if the machine is a Vbelt drive, check out the ‘speed changing procedure. {it involves spanner work and bruised knuckles look elsewhere. ‘A Norton type screw cutting. gearbox is a must if you do not want to spend valuable ‘model making time changing gears each time a screw thread needs to be cut. Spindle speeds should range from around 30rpm to 2,500/3,000. On the faster running machines, make sure you only fit quality chucks and faceplates. Machines with a centre height over Sin. should bbe equipped with a No. 3 Morse taper in the head and tallstock. Better tallstocks are fitted with a graduated cross ‘ways adjustment to allow set over for taper turing. ‘The chuck mounting is important: On smalter lathes @ ‘screw on chuck is acceptable but on machines over 4.5in. C/H there is a fair amount of torque applied to a large chuck Under load and ! would expect a ‘cammiock mounting or the chuck fitted with a taper back plate held with a screwed collar. Bed design is usually one of two types: Double V or fat, both have thelr merits. | prefer a Vbed but bed design does not determine the machine's quality; there are mary very ood lathes using both bed types. However, a hardened bed is an indication of a well- built machine. Model Engineer 8 Apri 2009 POSTBAG Enticing young engineers SIRS, - My Model Engineers go back to about 41960 and have been read cover to cover often, Including the ‘ads.’ Comments on the decline n the number of younger members in model engineering clubs ae too frequent, {and there have been too few suggestions as to what may be done to attract these highly skilled people before the old-timers die off. It is desirable that the clubs continue to prosper, ‘and that oldtime knowledge may be passed on to future members. Well remembered isthe way, n the 19203, ‘so many things could be seen ‘being made’. ‘par from visits to factories, slowiy walking by blacksmith's shops, and printers, as well 8 watching shoes being repaired, are a few. Moreover mary machines, for example a steam shovel, were constructed with chains, {and cables and shafts exposed, so there was no mystery about how they worked. Such things as bridges were of ltice construction so the bracing was apparent. At home, with the good fortune of having an engineer father, and ‘wonderful mother, Meccano, and socalled ‘toy’ stationary steam engines, without emphasis on 10” gauge clockwork tains; as well as lots of lumber and room to build things an Interest in model engineering came naturally for me as it must have done for mary others. Today all youth are not merely Interested in ‘pushing buttons’, At our 75 yearold Toronto SSME we have one young member who has exhibited, and ably described, devices he has made, for example a tiny lightseeking robot. Other Items in this category have a modem attraction encouraged by world competitions. While decrying the destructive nature of the Robot Wars there are other admirable ‘examples such as making a robot that can ‘enter @ maze to locate and extinguish a candle in minimum time, Another good one ‘seen on TY was robotic soccer players about the size of one's fist that could ‘kick’ a ball with a rotating drum. Two teams made quite a show. This kind of pursuit can encourage younger membership in model making clubs, ‘but It Is not the oniy kind of attraction. in the Toronto SME we have two members who have ‘made remotely controlled robots that can go perhaps 50 yards away on a tricycle and react (talk?) to individuals as though they were alive. Making sleek bodies for model cars these days can be admirably artistic, but itis not on the engineering side. You don’t see the gears going round! It takes experience to appreciate the Work of making louvres. Young people today ‘seeing digging done by hydraulic machines lack a ‘feel’ for the stresses and strains put ‘on the shiny cylindrical parts. fold hands ‘made models of these they might inspire youngsters to havea-go. Working out whether to have the hydraulic pumps aboard the model ‘rat the control place with control through ‘multiple tubing, Is food for thought. However, ‘a remotely controlled model of a front-end- loader, or backhoe, should be able to foster the desire to make a model “Just like the real fone"; and of course seek out kindred spirits ‘among model engineers. This kind of approach especially at ‘exhibitions can entice younger people to explore their abilities as well as seek the help Of the more experienced. John C. Chappell, by email. Ergonomics: This fs the part where the men are sorted from the boys; in terms of machinery that is! Ifyou are a person with little or no knowledge of machine tools and their operation you really must get some help ‘and guidance. Please do not make the mistake of thinking that buying a new machine of far eastern origin guarantees perfection. Many machines when set side by side will look the same and match up to the criteria above in terms of specs and performance though some machines will perform better than others even on the same tasks. Performance Is hard to quantify as It is largely down to the user though some machines will do with ease What they are designed to do, land much more, the Myford being a good example, whilst others will struggle. Machines with a good pedigree from long-standing and respected manufacturers will have a special fee! to them. can give one example: A friend of mine, not highly skilled, working with me fon a development project always insisted on using the Chinese lathe in our project workshop concerned he might ‘damage my personally owned Colchester. On one occasion, with the Chinese machine being occupied urgency forced him to use my lathe. After a lite while he tured to me saying “What makes this ‘machine so easy and nice to use?" The simple answer Is the bulld quality/ performance along with the ergonomics, control levers that easily come to hand and operate smoothly ‘throughout their range. Even (on a large machine when using a small diameter dri, the dril’s progress through the ‘material will transmit back to the user via the handwheel. The same will apply to the cross and top slides; the ‘operator becomes one with the machine. Because a machine has ‘an unknown name does not necessarily make ita bad ‘machine. When inspecting ‘such a machine apply the criteria suggested above along with tips given in my article Choosing a Lathe - ME. 4301, June 2007 and pertiaps do a web search backed up with a letter to ME. Posibag Harold Pearson, ‘Cambodia. 435Traction Engine Lamps mh ceeaes fg oa tgp na i brass which sounds 1 eerie ep tro aan sy — wena | | : | & Se ee Tony Meek concludes | the stip square tothe direction y the series by fishing | iz Brey 20.015 oop g the doors, windows x Yin. wide groove was milled = and lenses. ina 2in. length of 12 x 4mm steel strip, so that the strips 004 HEE FR: PART3 cout eal be camped nthe Se Svan ste me Continued from page 381 partially formed. DOOR HINGE (M.E. 4348, 27 March 2009) ‘To help with this part of the MATERIAL: 0.018in BRASS. pom rope ae mo mare ito are ; Serpe osnmath 4) ] ro meus mosecron Most evs mre eo west Os, A small witness was left on ‘sure that the rolis were evenly to complete the roll (photo the top of the radius to ensure ‘tapped around the former ‘37 and fig 11). incidentally, ‘squareness’ was preserved. (photos 35 and 36, and fig 11). when making hinges, | found thantctesaneatee "Tocinte whimsy. Resmaan toe ar contecisi teres” wmnmrecitonbewens smmiaebre an placed in the groove with just a length of hinge pin material —_ unblemished surfaces both on Grprnwarivcentaoe decthaatoanson Sememdcnsernar Geispermeronet tar” frunea vowten’””—Mstliah mean ta the roll of the hinge (ust over clamped vertically in the vice to be removed and cleaned up. half of the circumference). The with the edge of the roll level__or tomake new ones. strips were clamped in the with the top of the vice jaws. not enough brass was Vice and the exposed material A block of material was placed peeping over the top of the tapped over using a small behind the unstanding strip former, so that the roll was not ‘square faced hammer, making and pressed forwards 90deg. completely formed, then further, cutling can be achieved by fare ee Popping the job back in the vice BENDING MANDREL RADIUS OF and bending it over a bit more Le | terete tos tre wae ee eed gimatera rae short straight region (0.20in. in edb Scere i mace teres Saal ecegnenns Seen Seer, were kept together as a pal. This sa procedure was repeated until i ‘there were enough rolls to make ® ®@ @ note oF MATERIAL the hinges for three lamps. THICKE: “The next step was to remove LESS 0.005in | parts of the rolis to make the HINGE MAKING SKETCHES HINGE hinges. | found that these small hinge parts do not take too 6 Model Engineer & Anti 2009kindly to having bits milled out of the rolis and that the use of a good square needle fle did the job better. This was wiiere nce clean vice jaws help. ‘To start with, the first piece of hinge was clamped in the Vice with the roll pressed fimily against the top of the vice jaw. The marked area in the roll \was filed away until the top of the vice jaw was reached. This should give a fully opened angie of 270deg., the angle at which the hinges would be wnen the doors are closed. | found that another Sdeg. or so of opening ‘made fitting the hinges easier, 50 instead of pressing the rolls down onto the top of the vice Jaw, | pressed them down onto '2.0.040in. feeler blade on top of the vice jaw. The blade was then removed and the hinge part was again fled down to the top of the vice jaw (photo 38 and fig 11) have made many hinges this way and although it may ‘seem fiddly forthe first pit it becomes easier and a full set Is soon made. Door bolt ‘The door bolt guides (fg 12), wore made in the same way as the hinges. The door bolt (i 113), was made from the same ‘material as tne hinge pins. It was a simple wire bending exercise, using a bending Jig using pins ‘mounted in a fat plate. Door assembly With all the door parts made, the door assembly was completed (fig 14). When ssoft-soldering on the door bolt guides and one half of the hinges, a long length of hinge pin material was threaded through them to ensure ood alignment when the corresponding hinge parts were soldered onto the box (photos 39 and 40). ‘This door assembly was then used as a jig for soldering the other haives of the hinges and door bolt guides to the lamp bodies - taking great care to avoid soldering hinges and pins together. In cases like this, | always coat the areas where no solder is wanted with Tippex Hinge stnp held informer ready for bending The roll completed over a temporary hinge pin. LAMPS Fang away the middle section ofthe hinge. correcting flu. Model Engineer 8 Apri 2009 035 J] O15 0562 0.218 ‘O9a7 cry DOOR BOLT MATERIAL: 00.040in STAINLESS STEEL WIRE DOOR BOLT GUIDES MATERIAL: 0.018in BRASS od THIRD ANGLE PROJECTION ay ‘Ainge soidered onto the box The fished door bot n postion. 437 >Handle & The Randle was forme tom a 8 FIT LENS ANO ROLL FRAME EVENLY AROUND THE LENS CHAMFER pee of bet it tal : (igs) Bas coud be use, | i but | choose steal as itis much stiffer and would resist some ofthe knocks that handles are subjected to, From photos of fullsize lamps it is not dear how these were fixed into the bodies. o | opted for an arrangement. 1 where they could be fitted after the rest of the lamp had been J finished and painted. Small blocks with ABA studs were silversoidered onto the ends and held by small nuts on the Inside. They could be soldered {4 directly into the top of the box, H 4 although whatever method is. Used, remember to put the fixing holes in the top before the vent assembly is fted permanently in lace (photos 44 and 42) Mounting brackets ANNEAL FRAME BEFORE SOLDERING ONTO D00R ieee oe 16), but could be adapted DOOR, WINDOW, HINGES AND BOLT GUIDE ASSEMBLY Sielawegies = C1 o167—+| 0.337 o.187—+| "ozet ‘The last components to be constructed were the lenses and sideligh windows. Botn were made ftom clear acrylic (Perspen). The windows (ig 417), were cut from Sm thick sheet and were a snug tin the bezels. Thy wero then chamfered so that te lower ledges of the chamters were about Yan. below the top edge othe bezels. To get ra of fle 0.04 and machine marks, the facos were drawn across a pece of 600 gt wet or cry paper on a fat plate. They were then polished using a Brasso loaded Cloth, Since the bezels were Sil soft fom annealing, the edges could easly be peened Over onto the chamifers to old the windows in place. The lenses (fg 18), wore It tuned fom ecrye reusing a form tool made ftom apiece of t gauge plat, The machine marks SEA were soon removed nthe late with wet ory’ paper, using fer and fier grades unt a ‘i marks were gone, ten finally t polished with Brasso (photo GE} mano mare rrosecrion HANDLE 43), Simian, the fnish on the MATERIAL: BRASS OR MILD STEEL SHE ae NBETe igh pollsh ona ft plate, to ensure good ight transmission. o188—~| O50 wll | L-o1s6 0107 1 Model Engineer & Anti 2009LAMPS = 425 LAMP MOUNTING BR MATERIAL 0.032in BRASS. Oa JACKET “MAKE 2, LEFT HAND AS SHOWN AND 1 RIGHT HAND NB: THE BRACKET FOR THE REAR LAMP MAY BE FITTED (ON THE REAR FACE OF THE BOX Handle pars sive soldered together. The windows and lenses Were fitted after the lamps hac bbeen painted. | had intended to use a pustrst for the lenses, but a moment of inattention resulted in a sliding fi, so | had to use super glue. Great care was taken not to get any on the polished surfaces. ‘The inside surface of the rear amp was coloured with a red ‘maglemarker’ pen. The affect, \was quite good, but a piece of transparent red film would probably have been better. Mumination ‘Most of the fullsize tamps 1 have seen are painted black on the outside, so | dd likewise. ‘The inside appears dark which ‘may be due to blackening by a pareffin burner. However, | painted the inside of mine white \Which gives the impression that the lamps are it (photo 44). The finished lamps are shown in photo 45. Lenses polished and ready to ft. Regarding active illumination, | may well ft LEDs at a later date. | wll probably use two Ineach lamp - one for the forwarcHooking ienses and the other for lighting the sidelights. These are directional devices 0 they will have to point ‘end fon’ towards the lenses and sidelights to get the best effect. will need to treat Illumination as a separate project since lam not yet familiar with the use of LEDs- a few more new ticks for an old dog to lean! ME oo EA fen i Riese SIDELIGHT WINDOW MATERIAL: 5 - 6mm ACRYLIC FoaI2 90532 WY te FRONT AND REAR LENS MATERIAL: ACRYLIC FRONT - CLEAR, REAR - RED Afnished lamp with the door open ‘A sot of hee fished lamps. Model Engineer 8 Apri 2009 439i‘ Graham Tebbs reintroduces steam toa school. (ne of the fished engines. Work as a Design anc Ina steam engine project and exception was the dedicated Technology Technician 50 asked our Head teacher, cast base. Allin all the boys at Egglesciffe School. Mrs Dame, about starting a learned a multitude of skills, The school is an 14.18 lunchtime Model Engineers’ including lathe work, miling Comprehensive situated between Club and she agreed. I started machine work, ling, tapping ‘Stockton and Dartington, near working with two year 10 boys, and thread cutting, riveting, to Yarm and close to the original Thomas Eddington and Matthew sawing, fling, sheet metal ‘Stockton and Darlington railway Lee, both 14 years, It work, Soft and silversoldering line. I was looking through our quickly became apparent that and fitting. We hydraulically department library one day and rot only were they keen but _tested the bollers and ater Cvs Watt (left and Alex Sanderson discovered a book entitled Model also very capable. Thomas did painting, the engines were (right) preparing the mould for Engineering for Schools by TE. not miss a lesson despite a run on compressed ai. With a a baseplate Haynes. Itincluded a model of broken ws. ite fine tuning and the safety ‘an oscilating steam engine with The original engine had a _—_valves set, the engines finally 2 spitefred horizontal boller.On_ pressed stee! base but, as ran on steam. loser examination | noticed it we have a foundry, | made a | was impressed with the was of robust proportions with pattern up and the boys did boys who now have a quality {food size bearings. Altogether the moulding. | poured the engine that wil bring great this was a really tractive litle casting (for safety reasons) and pleasure to them for many engine. the boys finished fetting the years. We are now onto our | ancled a rest from my 3in. castings. The important thing to third pair of engines, with more ei oe Allchin so | bulla model engine emphasise Is that the engines applicants than places, but The dag rammed up with the for my grandson. Several pupils are not made from a “kit" but for safety reasons, two pupils, patter and runners. ‘at school showed an interest from stock materials. The only is @ good number as | can 440 Model Engineer s apn! 2009STEAM IN SCHOOL supers one on @ machine waist the other Is doing hand Work We nave boys In years Band 9 wenting to bud engines bul year 10 ls 0 good Sos 0 York ont rmctines. because I foar 1 Uey be too buey wth exams and coursework We ae forunste fon deminer io hee Harigon 140 vente late, along wth two Boxer, a Harton nrzonal allog machine win avertal nao, (ed a Rlamefast DS200 brazing te Se hearth and a Flamefast fied Joe Weston (Jeft) and Tom Osborne) bruce furnace with foundry gt satngup be fae on be equipment, as well as all mmiling machine. the usual D & T equipment consisting of Boxford pillar a group of youngsters (and drils, bandsaws and Union _—_grown-up youngsters) being Graduate wood lathes etc. entertained with his model (Our Head of Department, Mt. steam engines. Dermis is a Hydraulic testing the bole. Pattison, fuly supports the club. founder member of our club, This project is more important a devout model engineer and turbine and a steam-triven comes to making injectors. The than first thought. Traditional honorary member of the Tees hydraulic ram which bends, pumping station is also home ‘metal working ski in Cottage Pumping Station 4in. nails for the youngsters _to the Cleveland Association Constructing these engines have He hase fascinating setup _to take home. He explains of Model Engineers with been safeguarded at atime which Includes a steam-driven the workings of the Injector. permanent Sin, and Tin. ‘when such skills are no longer dynamo which lights up a logo with working examples he has gauge track and clubhouse, part of the school curriculum. which the youngsters nave to. made, his smallest has tobe _they also encourage youngsters Tam a member of ‘The guess the meaning of, a minute seen to be believed. Dennis is in thelr activities. Allin all itis Northern Miniature Road Divalve steam engine, a steam the absolute master when it an interesting day out Locomotive Society’; we have approximately 40 members and 12 junior members. One of our aims Is to encourage youngsters into the hobby. They are taught how to ative, ‘maintain and look after steam tengines, In fact some of the Juniors have been driving longer than some of the “Old Hands’. As our name suggests we are mainly road steam orientated, with two of ‘our members being fullsize engine owners and we attend various steam rallies in the region and beyond. Some of us are members of local model engineering clubs as well. Tees Cottage Pumping Station at Darlington Is a Venue which some of us attend on open days. it has an attractive building which houses a majestic beam engine built for pumping water from the Tees for Darlington, with coal fred Lancashire boilers built by Teasdale Brothers of Darlington. After climbing the Stairs to the top floor to see “The Beam in operation, you will ind Dermis Sutherland with Thomas Edington (let) Granam Tebbs (middle) and Mathew Lee (nght) with thet fished engines. Model Engineer 8 apn 2009 aan‘ ‘ 1 the sand until the chairs were father, my grandfather, drove n Engine Driver's ==> ssxmere= re are ine ofthe larger bakeries safe distance and wat forthe and that his mother, my sand to erode until the chairs grandma was a char for one collapsed ito the hole, much ofthe many doctors that to the embarrassment ofthe hed and practiced, along cecupants who went over with a numberof solctors backwards logs falingin anon the Mosley Roady in those undignified manner. Later he days a very affluent area of moved back to Birmingham, Birmingham. My grandparents number of years ago which | understand had nothing had accommodation onthe top Thadthe thought of ‘to do wth his mischievous lor of the house that grandma putting into wing te behaviour In Weymouth, looked after coincidently exactly lots told me'by The majoty of Sia’ schooling opposite some shops, one of my fathor.a der for over 40 took place at Dennis Road which would later became A. Years with the London Midland & School, Bimingham where J, Reaves. Grandad told me an Scottish Railway andlterErish he studled from 1919 to interesting story that | balleve Railways. Unforunatey time 1922, leaving atthe age of is worth relating: the road Harold Pearson waits for ne one. combination 14. Photograph 1 shows his down through Digbeth from St. talks about his father | of my boing say rom the praiseworthy leaving certfeate, Martins Chure in Bingham Ukiorextended periods, an Earlier young Sid had taken Bull Ring is quite steep and in who worked for the tnexpected and rapid decine part inanationwide Engish those days was stl cobbled. LMS Railway. in my father’s health ana a txaminaton performing well The surface was treacherous at golden opportunty was missed. enough team hima unhersiy the best of tes, particulary In Therefore apologise to readers scholarship. Unfortunately the wet and even mare so when forthe occasional lack of detall__his relatively impecunious Igy. Aforse drawn brewers day 28 the information depends upon background would nt allow coming down the hil ran away ‘memory from times when, a8 a_i to take advantage of on the ly oad fetching up Young boy, | woud sit and isten the opportunity. 'minclined outside Birds Custard Factory a5 ny father eiated some explo to think tat in these days na mass of broken shafte and of other to my mother, a friend it was engineered that way tangled harness (the building forme, Some of the recallections to keep the “i raff" out of__is sil there and may now be ae no alway related but fee! higher education, knowing very listed fr preservation. The ae stil wort the teling. wll that scholarship ornot horse, a wonderful big cart ‘My father was bom in the youngsters from poorer families horse, suffered a burst artery in Mosley area Birmingham in1908 would have a hard time affording one of its front legs. There was ‘and christened Sidney George the other expenses incurred in aa lot of shouting, with people Gerald Pearson. He was known to university education. running about when a small ny mother as Sid, tohis mates His first job was with a group from the custard factory a8 George and to me as dad. ‘Tyseley located spring mattress came with a wooden barrel ‘AS a young boy Sid was sent company as a messenger/ and several sacks of custard to live with an aunt in delivery boy. He worked with _—_povider. The horses injured Weymouth, where he this compary for about three leg was placed inthe barrel also attended junior years. However, he left when the which was fled with custard school.One story opportunity arose to become a powder, almost immediately the he told me was of leaner with the London Midland bleeding stopped. Throughout his exploits wth and Scottish Railway Company the whole drama the horse had ‘friend, who on (LMS) based at their Duddeston stood quiety wit its handler Sunday mornings Mill Road, Saltey Depot. The stroking its head, whispering He ‘au | Would go down to mattress company manager words of comfort. (oo ci-aiitels | the beach where gave hima glowing reference por’, \ well dressed ladies saying that he was a “Verysmart AS a cleaner oh 2 \ ofthat period young man who would go far". nthe scheme of things liked to lounge int interesting tonote that the cleaners were pretty lw in eckchairs, taking mattress company ater changed the pecking order, even within Inthe moming its name to something encing the cleaning disciplines there sun, The two im Landi to become one of the were those at the top of the boys would creep largest manufacturers of ts kind ple and those at the bottom! Up behind the inthe word. Dad remarked to Generally the youngest and unsuspecting me on several occasions that____newest found themselves with : ‘sun worshipers he wondered if he had not made the ditest jobs; cleaning out i ‘and undermine a big mistake by leaving the _freboxes and ashpans, smoke bam @eveatio’ Camnitee SCHOLAR'S LEAVING CERTIFICATE tip ity of Bir eS facta 908 cot it anctlligent Gove Remo — S| the rearlegs of company when he did, boxes and tubes, washing out = ‘theirdeckchairs 1 know very ttle of dac’s boilers or down in the pits ye | ty digging away early life other than that his shoveling out the ashes. AS a 442 Model Engineer 8 April 2009cleaner moved up in status he \Would be called upon to actually Clean the locomotive. This was generally carried out with two lumps of cotton waste and ‘some (vegetable) lamp oll. The oll was applied with one lump of cotton waste and the oil and dirt wiped off with the other, Locomotives used sand under the wheels when extra grip \was required. The sand was applied via sand boxes on the locomotive through a pipe that extended down near the rll, just In front of the driving wheels. ‘Sand was encouraged under the \Whee! with a steam jet located at the sand ext point. It was important the sand was very _ something that was handed dry and locomotive sheds had out Ike confetti in those days. ‘ovens for this purpose. It was a After a while the locomotive cleaner's job to keep the ovens came onto the shed and was Working and filed with sand, duly parked over a pit. With When a driver or fireman did some trepidation the two not tum up for work, a cleaner cleaners went down the pit Would be sent off on a bicycle steps under the locomotive, tolocate a replacement. iffor which | understand had inside ‘some reason a replacement _cylinders and motion. They Could not be found, @ lucky were both surprised to find cleaner could find himselt very Itle evidence of what had pressed into service as a happened: in fact all there was fireman. In some cases crews to show of the event were some lodged away from home and —_ bits of cloth. This was probably Cleaners would provide a wake due to two factors: firstly, the Up service. | temember my dad train had been at speed at telling me he would ride round the time ofthe incident and fon a bicycle with a long cane to secondly, there is not much tap on bedroom windows. Clearance between the frames Just after starting a cleaning with cranks and valve gear shift, Sid and his mate were fying round, rather ike a glant called into the foreman's rmincer. Sid and his mate office, which usually onty ‘completed the job and had the hhappened when trouble was _rest of the day oft. afoot. However, on entering {A stunt young cleaners that sacred ground they were used to get up to during the relleved to see the foreman cold weather was to take \was of pleasant countenance, thelr breaks in the fe box Infact he was smiling. “Ihave of an out of steam but stil a special job for you two, and warm locomotive! Along with When you have finished you the grub out would come the ‘can have the rest of te day dominoes or cards. | am not off’ Sid and his mate looked sure if| would like being inside at each other and, probably _a locomotive fre box, a bit too simultaneously asked “What's claustrophobic for me. the job?”. “Well t's like this lads" continued the foreman AS a fireman “Apair of young lovers have AS a young fireman his thrown themselves under an _ immediate boss was the driver ‘express train and the locomotive who expected him to report for {s coming into this shed to duty one hour betore official be cleaned!” They could have booking on time to make sure refused the job but it would the locomotive was properly Rot have gone down well with prepared. When the driver arived the foreman, In any event, he would inspect the locomotive half a day off with pay was not to see all was in order. On one Model Engineer 8 apr 2009 ENGINE DRIVER'S STORIES ‘cocasion dad was called over nd ticked off for not topping Lp one of the sand boxes to which he replied that it was already ful? The driver pointed ‘out that he had left a piece of cotton thread on top of the sand indicating the box had not been topped up. On another occasion dad was sent home to change his shirt from a light blue one to ‘white one with a black te! Working a breakfast special from Birmingham to London Euston the footplate crew found themselves against the butfer stops in Euston having made good time. Passengers were streaming by, mary of them city office worvers, giving a cheery wave or @ ‘Thanks for @ good trio driver’ alvayys well recelved. On this particular morning there was ‘one chap, dressed in pin striped trousers, frock tailed coat, high collar shirt, bower hat with brief case and cane, rather like Charlie Chaplin. As he passed the locomotive he gave the arver ‘very sour, superior look. The driver sald to dad ‘Look at him George, | bet he’s a miserable Intlo s*q’. Dad enquired ‘How do you know that’ Because his badkside doesn’t fi his trousers!" was the informed reply (said in a loud voice so the intended recipient would hear i). As a driver Around 1937 dad was transferred to Leighton Buzzard on light duties as an assistant to the signaiman. This was due to a back injury caused by a fall from a stationary locomotive. Thave often wondered it said duties Involved hauling on signal levers, if it di then | fail to See how such activities were helpful to a back injury? (One warm Sunday morning the toottoot toot ofthe local hunt came wafting through the windows of the signal box. Riders and hounds on the ‘opposite side of the tracks were heading toward the rallway line in pursuit ofa fox. The fox was ‘making good time, his long red tall streaming out behind. Upon reaching the tracks old Reynard crossed the rails, making @ bee line forthe signal box, or rather the chicken coop along side the box where the signalman kept a number of chickens that provided his daily supply of fresh eggs. Foxy scurtied under the coop, the floor of which was raised a litle from the ground, In the meantime the hunt had come to a standstil across. the tracks, | assume because they were not allowed to cross railway property. I's pretty clear the fox had worked this out With the added precaution of anifty hiding place under the chicken coop! The signalman (often known as the Bobby) remarked he had witnessed the ‘occurrence several times and was very surprised the fox never persecuted the chickens, the fox, perhaps knowing very well when he was onto a good thing. Whilst stationed in Leighton Buzzard dad met my future mother who was working as a domestic in the lodgings where dad stayed. They were married that year at St. Barnabas CChureh, Linslade. Photograph 2 shows the happy couple in ‘compary with Mr. and Mrs. Bowiey, proprietors of the lodgings. The Bowiey’s became ‘rm family fends whom we sed to visit during the long ‘summer schoo! holidays. It was Mr. Bowiey who introduced my father to fresh water angling. In 1939 dad retumed to Birmingham where he and ‘my mother took up residence In their new semi-detached house in the Yardley area of Birmingham. | was born in March 1941 and | am so glad | was too young to know what was going on at that time! (@1o be continued. 443diving wheels, Twenty of these locomotives received the new type of boiler and became in effect a new class - the Bulldogs, named after one of the frst locomotives to be ‘80 treated, The combination \was evidently successful as the Bulldogs were added to in considerable numbers by ‘new construction; the class eventually totalled 126. Generally speaking, the Bulldogs had a relatively long ‘and useful fe, several surviving into the British Railways era. ‘No. 3405 Empire of india was withdrawn in 1937 but, lke ‘mary ofits stable mates, survived for several more years in a different guise. Around this period, many of the Bulldogs were fitted with a less weighty ‘Close-up ofthe fished model showing the detailed fnish. _boller in order for them to work over routes demanding alight Improvements to the locomotive axle loading. These boilers were fleet. His focus at the time was of a design dating back to the (on bollers and in particular, 2 1880s and originally associated type of boller he had seen whilst with the Duke of Comwall cnavisittothe USA. These cass. The result was a hybrid Bolers were equipped win a locomotive, having the boller te fullsize Empire large frebox, and a tapered of a Duke and the chassis of of india as bulk at barrel, On his retum to Great a Bulldog, thus were born the Swindon in 1904 and Britain, gained authorisation Dukedogs. vasa member ofthe forthe production of anew type ‘Fortunately a Dukedog has 33ecclass; they were better of baller that combined the _sunfived into preservation and known as Bullogs. though US style of tapered barrel with is shown in photo 4. Bulldogs the history ofthe Bulldogs the Belgian ‘Belpre’ type of however became extinct in s is ong and complex, the frebox, First recipients ofthe 1951, leaving the GWR flagship Alan Crossfield abbreviated story can be taken new boilers were some of the Gy of Truro as the nearest relates how he took {pin the late 1800s when outside famed 440s, then _sunvng relative, The Cy class George Jackson Churchward handing most ofthe GWR's were bult during the same over an abandoned was principle assistant to main line workings. These period as the Bulldogs; they Bulldog which he Wiliam Dean, Chiot Mechanical locomotes were a mikod bag had 6f. 8¥n, ving wheels Engineer ofthe Great Westem orsisting of several classes, and cared slighty larger skilfully tuned into an) tay. chuchward hed been ene of whch was the ule of baller Many features were award-winning model. | given a ree hand to implement Comall class with 6f. 8in. common to both locomotives, including the footplate layout. Photograph 2 shows the finished mode! and photo 3 is @ close-up showing the excellent finish. Photograph 4 shows ‘some boiler backhead details of City of Truro, Both the preserved locomotives were to become an invaluable source of reference throughout the construction period of the model, Origin of the model Bill Whittaker of Bolton began construction of the model in 1978. | suspect that Bill's Inspiration came from the publication of the design and description by Kelth Wilson. The 444 Model Engineer s apn! 2009EMPIRE BUILDING Eo just ahead of dates cartier members had__rghty or wrongly. AS Iwas the leading _strengthening plates riveted to dealing with an abandoned coupled wheels. thelr fare exterlors, ‘Project, | Began to suspect the From this (nthe model, both the lator. Due to this uncertainty | Doint forward, inner and outer frames carry decided to delay the assembly the frames strengthening plates inthe ofthe mainframes untl had ‘Joedle inwards vicinity ofthe main crving axe. completed both the onder tobecome Strengthening plates are also block andthe erankawl. The narrower; thus fitted tothe frame area around —_oylinder block would provide creating he the rearcoupled axle but on rigidity forthe inner frames allimportant the outer frames only. | was whilst the orankanle would act clesrances unable todetermine the exacts judge and jury in any issues Tequied or the date on which the stenetnenine of alignment. sideswing of plates were fited to the original thebogle. The locomotive. A photograph of the The cylinder block inerframes fullsize locomote dated 1907 Both the olinder block and then continue reveals that strengthening __the steam chest are of cast forward and plates had yet tobe fted. Aiton, The complete assembly remain parallel further photograph of 3450 _ situated between the two toa pointjust_ in 1925 dearly shows the plates ofthe inner frames ahead of the strengthening lates ftted and is secured by a total gxiinder block, but offers no information of 26 hexagonheaded - From this point as to when this took place. _setscrews. The ajindor Fullsize cab figs onthe forward they taper inwards Photograph & shows the inner bores are 1.Sin. la. and are Gi off. slighty and make a straight line mainffames and the lechenc- designed to accommodate towards the font butter beam. site outer frame plate. a sttoke of 2.312 inches. n serialsed articles appeared By using double frames an arrangement where the Jn Model Engineer between the GWR was able to provide A bad start steam chest lies beneath February 1978 and June 1982 the normally vulnerable crank From a constructional point the cylinder black Itself, the ‘and offered builders the choice axle with four axle-boxes. This of view, the obvious way to port face and valves maintain of producing elther a Bulldog meant that the stresses in restart the project would ‘a horizontal atitude to the ‘or a Dukedog. Now, 30 years the crankaxle could be greatly have been to complete the ocomotive's chassis wiilst the later it would seem that few reduced and with them the risk assembly of the mainframes. _oylinder bores are inclined by Dukedogs and even fewer of fallure. Moreover, as each ‘The procedure however proved 10 degrees. This follows the Bulldogs have been completed; driving whee! had a bearing on frustratingly difficult. | also had arrangement on the fullsize in fact, just prior to the each side of it there was a good concerns about the longitudinal locomotives and is an excellent completion of my own model, chance that in the event of a integrity of the four frame- fone for a model in that both keith Wilson himself informed _crankaxle failure, the wheels plates. Iffor any reason there cylinders and steam chest can ‘me that he was unaware of would remain on the track. was misalignment of the four be drained from one point. in any completed Bulldog in Sin. Variations within the Bulldog axlebox guides, the result ‘addition, as the valves will drop gauge. Bil’s model appears to class were numerous and would be the very opposite of from the portface when the hhave been abandoned during —_wide-anging. Worst ofall, from the original design concept regulator Is closed, a snifting. the early stages of chassis ‘2 modellers perspective was -a stressed crank-axie. At valve is not required. Construction. Bill Whittaker the fact that individual class this stage, all the alignment Photograph 6 shows the himself moved on to other members underwent several holes in the insideto-outside _ inverted cyfinder block with, projects; he was a competent changes during their lifespan. _frame-specers had been pre- several steamchest securing: and active model engineer until As an example, later members drilled. This in turn could only _studs (SBA) in position. his death in 2002, of the class were bullt with ‘mean that the alignment of Note the close proximity of When | took over the project deeper frames whilst at various the chassis was fixed -elther the cylinder bores to the > n.2008 the locomotive frames Were in several parts and none the better for their 20- plus year’s storage beneath a workbench, The locomotive mainframes Both the inner and the outer ‘mainframes of the model are of Yin. thickness steel plate. Inthe plan view of the chassis, the outer frames appear straight and remain paralle! to each other throughout their full length. The inner frames are straight and parallel from the rear drag-beam to a point The inside ames together with one ofthe outside ames. The cylinder biock inverted Model Engineer 8 apr 2009 445rlling machine. Each ring was clamped to the table whilst a groove was machined across the full width ofthe face. The {groove was machined to a depth of exactly half the with of the ring itself whilst the width of the groove became that of the slotaril diameter, %s inch. The ring was then turned over and a similar groove produced on the opposite side. This groove \was carefully positioned offset to the first groove, so that when ‘machined to the same depth, the ring would become spilt as shown in photo 10. ‘Al four rings were so treated, the spilt in each, effectively allowing the rings to be compressed inwards and close the offset gaps. This procedure of course would render the ring to become slighty oval For the final stages of ‘machining, the Job was ‘Making blank piston ings. Homemade piston rings transfered back othe athe where the indvcual ngs machined outer-sides of the plate, the latter being held by are of silver-steel; the left ‘would be skimmed to the cyfinder block, Ateach end two TBA studs and nuts. The __Rand-side pin of the leféhand: fished diameter. Each ring was ofthe ovinder biock, short cylinder casting nas been drilled side crosshead being longer positioned onto a purpose But counterbores locate the front and tapped in order to acoept than the remainder in order mandrel the design of which and ear olinder endcovers. fourteen SBA sorews, These to reciprocate the crosshead would alow te tng to be sprung Tese components wil be sorews (seven each side}, vacuum pump. inwards to close the offset gap. secured o the block by GBA secure two lengths of steel Pistons are 1.5in. a. and of | Once on the mandrel, the hexagon‘eaded setscrews. angle. The steel angle in turn, _castion. Adescription of their piston ring was compressed Photograph 7's of the rear secures the smokebox saddle construction would Ifeel, yd by means of a circular sheath ofthe oflinder block with the by the same number of BBA Ite Interest tothe reader. Piston whilst a dsc was clamped end-overs in place. The rear screws. Also located on the rings.on the other hand may be against ts face. Wit the endovers are fabrications upper surface ofthe cinder acquired commercially orhome rng in its compressed state, that house the piston glands block ae the steam inlet and produced by several methods _its outside diameter was (O-rings); they also provide exhaust points. ‘open to the model engineer. then machined to the exact a tkng platform forthe The main steam inet Is {claim no ona fr the ameter of the onder bore. crosshead slidebars. tiweaded in. x 26tp whist __methed | have used but will pass On releasing the clamping disc, The ovinderdubrication non: the exhaust connection is by a iton asa series of simple steps. the ring would spring outwards return valve Is situated between manifold secured by four 6BA again thus maintaining the the two endoovers. sores, Producing piston rings __abityto exert a constant The steam chest is placed This is normally rather wasteful outward pressure on the bore of rectly below the onder block Steam chest drain cock —_—_interms of raw material and the onde. and following normal practice This item is ofthe tapered-plug the methed 1am about to ts secured tothe onder block type and is screwed directly describe is no exception; it Axles and fly cranks ony, The vahes are ofthe ‘D’ into the steam chest outer. does however differ from many Silver steel was used for pattem sldevale type. A%ain, cover. The basic simplicity cther methods in that there the axles ofthe locomotive. dla, stanlessstee! spindle dives afforded bya single drain-cock is no heat treatment involved. Components of the crank axle tach ofthe sidevalve buckles. was in this case, offset by the plece of centrfugally spun have been assembled using Both valve spindles are relatively complex operating __castiron was machined intially Loctite and pins. The detailed equipped with tal rods that linkage to and fom the cab. to.a diameter slighty above procedure describing their protrude through the front Mary components transfer the that ofthe piston itself. Te manufacture and buildup was of the steam chest, Slicon push-pull movements through a Internal diameter was bored described by Keith Wison MLE. Orings are fited to the three _restiicted route punctuated by to produce a short tube with a 3595. Points where the spincles Unhelpful obstacles. wall thickness of inch, Four protrude to the atmosphere, Photograph 8 shows the rings were then separated from The crank pins the right-hand-side front tall rod pistons complete with rods and the circular billet by means of a Each coupling rod crank pin has being contained within a bing crossheads. Each crosshead parting too! (photo 8). been machined from siverstee! extension bush. Each Oving is was fabricated trom bronze For the next operation, the and caries an extemal thread captive behind e brass gland and steel. The gudgeon pins Job was transfered tothe of tan, x 40tpl.Loctte secures 446 Model Engineer 8 apn 2009crankepins on the drivingaxle fiy-cranks, whilst those of the tralling axte (being nearer the hheat of the firebox) are an Interference fi. Crank-pin retalning-collars are threaded ta match the crank pins and have, as in full-size GW practice, the additional security ofa taper pin. Photograph 41 records the ‘set up to create the keyways and quarter the fly-crank \wobs. The lefthand end of the crankaxle rests on a Vee block \whilst the righthand end rests between the jaws of a machine Vice. The Jaws are making ony light contact with the axle, Whose weight at this point is Supported from below by a ‘spacing-block positioned within the jaws of the vice. The block hhas been adjusted to ensure that the awe Is parallel to the surface of the miling table. Ina previous operation, the Jefthand end of the axle has been milled to provide keyways. for both the driving wheel and respective fy-crank web. A rectangular length of steel bar thas been bored at one end and has a keyway matching that of the crank webs. This bar is temporarily but positively lengaged on the end of the axle using @ key. The bar and ade are then rotated through ‘90deg. until the bar makes positive contact with an upright Stop. At this point, the jaws of the machine vice are tigntened and the miling ofthe keyways repeated on the rightsiand end of the axle. A%ain. dal, slot drill was Used for this operation. To produce the keyways in the bores of the wheels and crank \webs, | produced a broaching tool from %ex Yasin, section HSS. This tool was adapted to fit the locked spindle of the ‘milling machine and used in Conjunction with the milling ‘machine quill. Wheels All the wheels on the locomotive have been ‘machined from high quality cast-iron, The castings \were commercially obtained and have been produced by the process known as Model Engineer 8 apr 2009 shell moulding, This allows. the backs of the spokes to assume the correct profile, ‘Separate balance weights were fitted to the driving ‘and coupled wheels of the locomotive. These were made from mild-steel and consist of an inner and an outer shaped plate for each wheel. The {wo plates sandwich several ‘spokes of each wheel and are ‘maintained in position by a ‘number of countersunk headed setsorews. Each setscrew passes frsty through the ‘countersunk clearance hole of the inner plate, then through a spacing sleeve, before finaly engaging with a 10BA thread In the outer balance-pate. The purpose of the spacing sleeve was to ensure that the inner and the outer balanceplates Were set parallel to each other. No provision has been made for the removal of the balance weights, the screws were ‘rimmed flush with the outer plate and the space between the two plates fled with resin, Photograph 12 shows a driving Wheel plus the front and rear segments ofits respective balance weight. The coupled wheels were ‘secured to their axles by a combination of rectangular Using Locte to secure the wheels, EMPIRE BUILDING section keys and Loctite 603. {twas the plan to apply the latter that consumed much of the midnight ol. The position of the driving wheels on the crankaxle was such that the ‘outer face of each inner axlebox ‘made contact with the inner face of its respective wheel, At the time of securing the heels, this situation was far from ideal, due to the risk of Loctite accidentally entering the adjacent roller bearing, The proposed method of avoiding this was to finalise the position of each wheel on its respective ale (key and keyway), then Inject the Loctite into the hub. Each wheel was prepared by driling a small hole between adjacent spokes. The hole was angled in order to break into the bore and connect with a circumferential gallery in the ‘midway area of the bore. A short length of copper tube was ‘secured into the hole by epoxy resin, & short length of silicon tube was then used to complete the transfer passage trom a ‘medical type syringe. After the ‘operation, the sacrificial copper tube was cut from the Job by sidecutters and the stump trimmed using a small fle. Photograph 13 shows the ‘method of injecting Loctite into ‘Awheel with font and rear balance weights. the hubs of the coupled wheels Due to the non-reversible nature of the process, I made the decision to paint the crankaxle ‘and wheels before commencing this operation ‘Axle boxes and bearings My preference would have been for castiron axleboxes \with plain bearings. Gunmetal castings however had been ‘acquired curing the original bulld period along with a full set of SKF needle roller bearings. As these items \were within my possession at the time, it would have been wasteful not to utilise them. The combination of gunmetal boxes and needle rollers has therefore been Used throughout on both the locomotive and tender. Axleboxes of the locomotive ogle were each equipped with an upper and 2 lower oll- reservolr. Photograph 14 shows a palr of axleboxes with hinged oil- lids fitted to the oll reservoirs. The steel end-covers are held In place by 10BA setscrews. Axleboxes of the driving.whee! Innerbearings have a *éin. stee! pin from which is hung the respective springhanger. (@7o be continued. A pair of alebores with hinged ods ted to theo reser. 487The Re-Cycle Engine ‘ow we will look at the construction of the cylinder assembly (less head), and the main reciprocating parts, the piston ‘and con rod, Let's make a start with the easy bits, the cylinder sleeve and the water jacket. Cylinder In the Interests of avoiding unnecessary swatf generation, Dave Fenner starts the cylinder assembly and looks at the main reciprocating parts. I chose to use a length of 1.25in, bore by 16 sauce cold dravm seamless tube. PART 5 The drawing (fg 14) has been ‘meticated and shows 35mm Continued from page 398 0/D and 32mm //D. A length: (ME, 4248, 27 March 2009) of this material is simply cut aiitle oversize and then carefully faced to a few thous. (ra couple of hundredths of a millimetre oversize. | was fortunate here, as the collet set for the Chipmaster will comfortably take this size (photo 42). Remove all burrs. 1 ‘am suggesting that the cylinder |s deliberately left large at this stage as the build theory requires that the studs will clamp the head - cylinder -base + stanchion parts, thus holding the oyfinder firmly between the i head and the base. Ifthe stack CYLINDER of tolerances works the wrong COLD DRAWN SEAMLESS STEEL TUBE way, then the clamping might be Via the water jacket, leaving the cylinder free to move a small amount along its axis. It sutable steel tune is not to hand, then machining from ‘a cast ifon bar should offer a suitable alternative. In elther cease, do ensure that the ends of the tube are machined square to the axis. Purists may want to hone the bore in the interests of perfect roundness. However, | ound the ‘as manufactured” tolerancing entirely adequate for the application. As a brief digression let me offera couple of examples ‘of how something less SI Songer te waren sacger erase a ree ecu ET ee auneet sane a reesei 48 Model Engineer & Api! 2009THE RE-CYCLE ENGINE fears which ed been on a az Site amreed telmt onan ve engine being assessed for life —F — Sears vores 1 [| J —pentaupasrae shart oyine arent oes, 5 ahs Butt fee point ou Sie that erga nebo mn meeting Its performance criteria, : ten fear fo pa 5 fore bt scongtond 8 oc eae Arather later automotive 1I— eaipsconateal sae 800, which | acquired around Ws ich To carvan oe thon teers bt had \ seers a nt Less oa oat arco ue Spare sl spo a hole piston. On strip down, SYUNDEP BASE aa Tro owl bunt one ‘aves ad hat ote hortendous amount of bore/ Water jacket cooling water inlet and outlet, (photo 44). Aim for a snug fit pisonwerTrepiserscoid Thematoralhere wasbrass {lla coup cfu.” Gach tine As the water ot be moved sideways by more ‘tube, 2in, 0/D, by 16 gauge (6.35mm) diameter holes at is sealed at the interface with than 2 millimetres. As a quick wall thickness (flg 15). The 180deg. as shown on the Its /D and the internal spigot, vngcesarestoiacoment ureonforticctuke wee, drags tion cotcolred in hate Rauded seal Soe Sgre,tononehenrcre becouet ted sone ofeus. twe'sett ings! curler” toma he salar: We se MonSupte suprcesen Youroage lusedtomelc passed venice bake fs spectiea but mine ists Mintbesscewecvetttoumi batches o'er tues which pes: Ihave chosen otto sbaut Sm ean he Dorstienrarteyec” wereused neananctonwtn ge the pecs pg atl, same deep. Stutwmautio sein dep Smallarmprccostodaver sottece maeluusncol Tho eethen moves tote at certain revs, but surprisingly dry air with which to pressurise by the location of the water ‘mill, (photo 45) to drill the: Dbrolconarplon Sone” conmutcaton Ines hese feswit Tefecet wit, far es nett on thee mane riscieca_yeremanfacured nie,” plpesle shown alongside the. Aren PO) Care shea be damcrdearwinalonmiengs Gemaers‘2n andncerd ender photo 43 thon emu tutte ch cerecutovadineront ine vata of rate fre ssc iscornoto nine a more comprehensive rebuild. different moisture removal Cylinder base ‘turned circular features. Teneclooesinywwe capes Rumeatpendinds “Me subiersrcnsions Slascusefpnate wrest “woul Gusset atin chunkofsene (127m) alm peanut rromedcratencvajos. or sodave of sar Stumm lteter miled trotascare our! wed While this degree of precision is dimensions would work just as to 2in, (50.8mm) square (fig __a Myford crip feed lubricator certainly necessary for small non well. One point to note is that if 46). Thinking again about this, salvaged from an old capstan ringed diesel and glow motors, EW (welded) stee! tube is used, after the event with the benefit lathe scrapped off mary years, \where the seal is entirely due this has a line of intemal welding of hindsignt,a slice of 2in. ago. | belleve that similar tothe piston -liner ft, when a flash which should be removed bar might also be used here. _ items are available from other piston ring Is introduced, we can atthe ends to avold interference Then, with the work transferred suppliers e.g. Chronos. The 'be more relaxed, possibly even a withthe location spigots. to the lathe and located in oller was supplied witha fting ‘ttle agrcuttural in our outlook. AS with the cylinder, make the 4,Jaw chuck, t can be Which looked a ite large to guess that the ring quickly beds sure the ends are faced bored through 32mm and ‘accommodate in the base, so in during the running in period to square to the axis and remove the location features for the an adapter was made to give an match the oylinder shape. any burrs. To provide for cylinder and water jacket cut M6 male outlet. Hence the base >> Cylinder and water jacket. Oylnder register has been tured, that forthe Jacket now n progress. Four holes are cilled to take the long stud. Model Engineer 8 Apri 2009 449Tod the ol way, a smal at was st cutwith an ond i, Embryo con ro clamped to bench for welang. Reaming the small nd bush. Work is mounted on| pacing to kop too’ tom contacting table. ores. 1-100 to protect the (prematurely fitted?) bearing. ‘Some additional work would bbe needed later to ensure clearance between the rod and ‘the oyiinder stanchion. The = | | completed rod may be seen in 3 | photo 49. 150 Piston, ring and gudgeon pin —_—| The general design given here (fig 18) was loosely copied from that gven by LG. Blackmore In his design for the quarter 760 I Fy CON ROD. [is shown with a blind hote drilled and tapped M6 to take this. it was then a matter of sighting Up and ariling a connecting hole with say @ No. 60 dil. in fact the operation was a ite ‘more involved, a frst, a small fend mill was employed to cut flat surface into which the dril Could be fed. if other prospective builders find an oller with @ ‘smaller outlet, then these detalls should be sultably modified to ‘uit. Photograph 46 shows the location ofthe ol gallery. To ease assembly later, | would suggest adding a generous 20deg. chamfer to the 32mm diameter bore on the face which wll abut the cylinder stanchion, Con rod ‘Again in my quest for swart minimisation and speed of ‘manufacture, I chose a two part welded assemoly (fig 17). No doubt, some will voice the 450 WELDED STEEL WITH PHOS. BRONZE BUSH cautionary note that this could In due course be the subject of a fatigue fracture. However at the low operational speed, [tis less likely and liable to be considerably less dramatic than the occasion when my 3.9 lite V8 put a rod through the side at 6,500rpm. Metallurgically, ‘2 welded joint is often likened toanas cast structure, so as I believe cast iron has been sed for con rods in the past, | ‘am happy to run mine with this: arrangement. Naturally a fair degree of care was exercised to ensure a satisfactory weld. Others may feet differently land choose a one piece fully ‘machined stee! rod My manufacturing sequence started with a piece of 30 x 16mm stee! fat, cut and squared to 33mm long. This was then bored 22mm dia. in the lathe to accept the needle roller bearing, 16mm /D, scale Bentley BR2 engine. He, however, opted for two rings, Whereas, based on What | see working well in miniature 2-strokes, have just one. | have also simplified the Internal profile of the piston, and added a Second cross hole, not for an oversize gudgeon pin, but to glve a better (Con rod mth needle roller and ‘opportunity for oll to ‘Phosphor bronze bush find its way to the small end. Work on the piston started 22mm 0/D, and 16mm long by turning the outside diameter land two of the corners prettled and internal undersice Up with fled radii. Actually, t features, after which it was ‘might have been wise to leave cross dled, reamed for the the boring unti iater,just in _pin, then returned to the lathe cease the welding operation _to cut the ring groove (photo Introduced some distortion. _ 50). As may be seen, this was The set up for welding canbe done using a narrow part off seen in photo 47. blade mounted in the rear ‘The rod was then driled and toolpost, and taken to a depth reamed to take a phosphor _of just over a milimetre. More bbronze small end bush, which metal was then removed from was first turned with the /D the underside by milling as lundersize with an interference may be seen in photo 84, from fit in the rod. The assembly _ which may also be seen that @ ‘was then set up on the mill simple txture was made to grip to drill and ream to match the the piston for this work. This 6.35mm gudgeon pin. This _fixture has not been drawn, part of the work Is shown in but the general form may be photo 48, where it can be seen deduced from a similar but that tape has been applied smaller item, made for the Model Engineer 8 April 2009THE RE-CYCLE ENGINE Jones 605 two stroke and ‘shown in photo 52. oe ‘Much nas been wnten in the past about ming piston 7 tings, Again take something Of a short ut approach which eco] 0 x20 a i Works for me. plece of old o1270 sash weight was chucked then yy 0293.0 faced and tured to 4.25in. 0/0 (to ust ft in the bore) for \ 0835— | perhaps a 6mm length. The 1/0 was then bored out to give a wall thickness of just under a millimetre. A length was J then parted off which would fit snugly in te ring groove. Se It its a few thou, oversize, work It gently on a sheet of Loni o7 a0 rt erry to reduced the PISTON thickness to ft. The ring was ACMINUM ALLEY then held gently in the bench ‘ice low in the jaws, so that Just a short length was held ro 19.00 mt 1 i and most was dangling in fresh 06.35 (06.35, ai Then pal of Bumerd Dural Jav ples was used toi the tig dose to the re ‘ee Jen end pantie pressure | L sled, bending The tng unl pibeEeNER 20 Tranapped, The rng was now GUDGEON Pa pened up to alow pleco of Brags on ALUMINUM Sian material tobe gipped Ih 20r ReaD the ge, holding the expanded form. Tho tg vs pecking Was now set upon frei, heated reg hot wth a blow torch, and allowed to cool. For te that’s the ed of owove am aware that others a fora Higher degree of preision and peter to start by mang the tng everatzn, then, heat in fature which ‘al maintain squareness, hen tocate Ina fishing txture to aly tum to sie. My simp views that ay sent inaccuracy wl soon vanish dhrg he running In porto. The eudgeon pin i simpy 2 piece of sive see, ct then faced to length and eles through to iten and also to tema te bees or aluminium end pads wich are nt a staigtorvard tuming exercise Photograph 53 shows this t20up of components, Als Stage t would be «good ee to neck the gudgeon pn lus pads for size nse the oyinder Dare te assembled length isa ot ty, just fle off aw thous, tocbian an eae (80 be continued. mir bt aml pon tue. Paton assent, Model Engineer 8 Apri 2009 451few years ago | coaches would be ideal, but | ‘completed a 10mm 's00n realized that my knowedge, scale model ofa British of BR coaches at the time was Rail Class 86 electric severely limited. I therefore spent locomotive and its construction a few months researching the was subsequently featured in various types and options. As the ME. 4342, 2 January 2009. Locomotive, 86104 Sir Wiliam A Following ts completion, ‘tanier was fnished in the Loco Ken Toone makes thoughts tumed to rolling stock _Blue of the earty to mid 1970s a take of coaches ‘and what might be considered perio, It seemed prudent to {38 a suitable matching oad. construct a rake of coaches, of a in Gauge 1 ‘seemed to me theta rake of similar era ‘A Brtish Rail second open Mk. 2F coach, Nore te ar condoning fan. 452 | well remember trains ‘speeding along the West Coast Main Line. They were finished in the InterCity blue/grey livery ‘and it seemed to me that these would be an ideal match {or this locomotive. The Mk. 2F Coaches first entered service in 4973 with 287 second open vehicles and 30 brake second ‘open vehicles being bull. A total of 58 vehicles were later converted for Gatwick Express use, However, although several of the Mk. 2F are still in use today, curiously no new Mk. 2 catering vehicles were fever built, Refurbished Mk. 1Lvohicles covered the bull. of the catering requirement Until a number of Mk. 2F Open Firsts were later converted to buffet cars. Therefore, a decision was made quite early on, that the rake would consist of five Mk. Model Engineer s apn! 2009Mk. 2F COACHES 2F second open coaches plus there were most helpful and fone Mk. 2F brake second open on a subsequent nonrunning coach. One of the reasons weekday visit, | was allowed to for this choice was the fact craw! about, wherever | liked, that these types were air as long as | was wearing the conditioned, What difference mandatory orange vest! does that make | heat you ‘say? Well, there are no opening Making the bogies windows in an air conditioned The coach bogies are to the coach so that the windows British Rall B4 design and In the mode! would simply be a start was made on these pieces of smoke tinted Perspex, first as they contained most coutto shape and fixed into of the high volume parts, ike place. Also, since the windows 48 wheels, 96 spring hangers were tinted, one could not see ete, and | thought | would get ln and therefore interior fittings these monotonous jobs out of Would not be required. the way first. bought a rather excellent The wheels were an easy book, British Rail Mk. 2 Coaches turning job from cut off blanks by Michael Harris and this gave of bright mild steel bar, not ‘much valuable information, forgetting to cone the tread together with detalled general diameter as per fullsize arrangement drawings of my wheels. | always cone my chosen prototype. wheels, regardless of size, {also contacted my local whether they are Gauge 1 or museum, The Birmingham Tain, as | consider that a Rallway Museum at Tyseley _better ride ensues. The axles and whilst they did not have are machined from 6mm any Mk. 2F coaches at the diameter stainless steel with time, they did have the earlier 3mm bearing diameters to suit Mk. 2C version, which at least needle roller bearings. hhad mary parts in common, The main frame of the full In particular the bogies. On’ _size bogle consists of two fone cold and wintry afternoon lengths of channel iron back to A three quarter view shawing the resin cast onds. armed with camera, tape back and spaced a couple of ‘measure, pencil and paper! inches apart. In the model this Duplex springing is used on _The primary springing consists Spent a couple of hours taking was recreated by machining _the Ba bogie and has proved to of two coll springs on each all the necessary details of the four grooves into a plece of | _be very successful axlebox ited around large bogies, which would at least. 6 x 1 2mmbbrass bar, to give Imust say, as an old hand sliding spigot locators, and this allow me to make a start. the same effect, rather Ike ain rail transport, | much is reproduced in the model, Later, | leamt that the double ‘H’ section. A plece of 6 prefer to travel in the relative with dummy shock absorbers Ecclesbourne Valley Rallway x 25mm brass does duty as the quiet and smoothness of (n each side. The secondary at Wirksworth in Derbyshire main bolster and two further _a locomotive hauled train, springing between the bolster hhad recently acquited a rake of channel sections make up compared with the constant and the main chassis frames is exGatwick Express coaches, the two ends. The whole lot is__drone from the diesel reproduced as a dummy. Some Which Just happened to be soft-soldered together to form a engines/motors of the current 3mm INA needle roller bearings the Mk. 2F version. The lads rig chassis untt crop of D/EMUs. are used throughout forall axles. >> ‘Mass production of the boges Ful-size bogie springs, Model Engineer 8 Apri 2009 453