Updated 2nd May 2010
We are currently building a brand new locomotive for a customer of a GWR 14XX 0-4-2- tank .As there are no details or castings for this design in 10 1/4" gauge we are producing our own including patterns. This loco is being built to a scale of 2 1/2" to the foot rather than 2 1/4" as the customer has other locomotives which he wants it to match the overall size. To date frame and wheel drawings have been produced including the production of wheel patterns .Castings have been made in cast iron and have since been machined.
Here we see the finished wood patterns prior to delivery to the iron foundry for castings. The patterns are build up from several sections of wood to provide strength and durability .The could is the special pattern varnish which protects the pattern from the abrasive sand during the molding process.
A driving wheel on its last machining operation being held in a 12" 4 jaw chuck and a finish speed of of around 80 rpm which produces a supper finish without chatter. The next operation is to cut key ways in the bore then bore the crankpin holes. All the wheels including the trailing wheels have now been machined. More pictures will follow and the loco progresses.
A recent batch of patterns made at our works for the 14xx ready to be sent to the foundry .The patterns are all made from Bass wood and consist of up to 15 pieces of wood from strength . The patterns are made to allow for shrinkage in the finished casting and also for machining.
Here we have the new boiler for the 14XX locomotive. the boiler was designed and constructed by Gerry Dowd ,of the Gloucester steam and traction company and comes with full CE approval .This boiler design is exclusive to Joe Nemeth Eng ltd ,so if you require a Belpaire firebox type boiler for a large narrow gauge loco in 7 1/4" gauge or a 10 1/4" 14XX or perhaps a M R 3 F then please enquire. Castings are now available for this loco should you wish to build one.
The crank axle has been fabricated ,pressed together and pinned for extra security ,and here we see the crank undergoing final machining to the journals.
One of the driving wheels showing the boring operation for the crankpin. Shown on the wheel is the jig which is used to locate on the axle bore key way to allow for clocking the position of the crank pin.
Here is the leading coupled wheel set completed and quartered
Here we see the finished driving crank axle up between centers for checking the accuracy of the crank after pressing the wheels on. I am happy to say the run out is within .005".
Finished split axle boxes in there horn blocks ready for fixing into mainframes.
Bob Symes ,with his 14XX chassis so far on his Green Dene railway for clearance testing.
The cylinder blocks, covers, valve and valve buckles covers and glands nearing completion. The bores have been honed to a fine tolerance and finish.
Recent work on the cylinder assemblies included finishing stuffing box glands, and making cylinder drain cocks.
This view shows slide bar sets and motion bracket finished. The crosshead bronze slippers are also fitted.
Another view showing the neat drain cocks and glands.
Now the cylinders are completed except for piston rings a frame drilling jig was made to facilitate boring out bolting holes. Here we see the cylinders temporary bolted in the frames for checking alignment. Note valve spindle guides which is based on the full size locomotive.
Another view of the cylinders, shame most of this work will be hidden away.
Here we see the big end forgings undergoing machining, yes forgings! These were made be heating steel bar white hot and forming it around and a former, the reheated to normalize the steel prior to machining .
Here we see the bearing halves being bored to finished size allowing + .0015". The fitted bolts are made from silver steel with hand made nuts to suit.
After many hours of tedious work one can admire the finished results, this has been one of the most enjoyable parts I have made to date.
The finished connecting rods fitted to the locomotive to see everything is in order. The rods have substantial split brass in the big ends and needle roller bearing in the small end for long life.
A close up view of the right hand big end and crank, very pleasing.
Here we the coupling rods have the the side faces machined, a jig has been made to facilitate this operation.
Great Western Railway locomotives have lots of distinguishing features including the coupling rods. Here the bosses are on the rotary table being milled with a bull nose cutter. The final finishing will be carried out with files and emery.
The rods fitted to the loco, all that needs to be done now is to make the oil boxes for bearing lubrication.
Back to the valve gear again, and he we see the steel eccentric blanks after splitting being rough bored in the mill.
After all major machining operations the finished eccentrics with the straps being trial fitted.
All 4 eccentrics now fitted to cranks axle, all that is needed is pinning their final position after valve setting.
Work is now progressing on the sheet metal work and here we see the finished front end of the loco,
Showing some of the early stages of building the side tanks. All the sheet metal work for the tanks, bunker and cab is in brass.
The smoke box has also been finished including opening tool boxes!
As per the full size the rear bunker calls for some complicated sheet metal work. Here can been seem the finished results of many hours of hand forming the six panels which make up the bunker assembly, all made from 16 swg brass. No hammer marks or car body filler here!
On display at Bob Symes birthday celebration.
Work has been progressing on the valve gear design and manufacture over the last few weeks and soon we will be able to fully assemble the cylinders, set the valves and run her on compressed air. Early signs indicate the valve events are within my design tolerance although much tedious fitting work has been done to ensure everything works together without and unnecessary friction.
A close up of the motion work, next item is to be made is the suspension links and pins to the weighshaft.
The ingenious thing about this design is that the cylinder block is split and incorporates the steam chest and valve in each. This means I can set the valve gear up on each side and be sure everything works before fitting taper pins. The same process will be applied to the other side and the both sets will be fitted together.
This view shows the completed valve gear finished and painted. The cylinders were piped up so an air line could be connected for air testing of the chassis, it runs well!
Bob and Sheila visited the works recently to inspect the progress and discuss some additional design features. Bob is well known in the model world for building some first class gauge one locos, and was the first to build a fully operational diesel electric , brush type 4. Then went on to build the first diesel hydraulic, both in gauge 1. So he has asked me to examine the possibilities of installing "Auto working" to enable Bob to be able to drive the loco from a driving car, just at the Great western did all those years ago.
As Bobs line is an out and back layout he has requested the fitting of a pole type reverser instead of the screw type. In the model form this make much more sense and makes for a more efficient operation when running around. seen at the base of the reverser is the drain cock operating lever.
This view shows the steam brake cylinder fitted and the connection with the handbrake.
An underside view with steam brake cylinder on the right and the 1/2 pint steam oil tank for cylinder lubrication. This is a pressure feed system and included a sight feed indicator on the backhear.
The left hand oil box on the front running board. This has 4 feeds, 2 for the axle boxes, 1 for the left hand crosshead and the 4th feed for the valve guide.
This pipe work was a difficult bit of design work and awkward pipe bending as it needs to be easily removable and yet keep maximum access in the smoke box for tube cleaning ect. The blast pipe has a combined blower ring instead of the usual bent copper ring which is easily knocked out of alignment. Where the steam pipe meets the steam chest a connection has been silver soldered at the rear to allow an oil feed pipe to be fitted. I always make the pipe work up with the smoke box removed.
work has been progressing at a steady pace recently, here we see the boiler fitted with cladding ready to install in the frames.
The boiler installed and pipe work is under way.
The pipe work is nearing completion, note the Billy can........
Here we see the wood pattern for the cab side with the brass castings beneath, one at first stage polishing and the bottom one ready to fit.
At last the loco is finished and waiting for our boiler inspector .
I will be posting more views with Bob testing the loco out at Ingfield manor Railway.
MORE UPDATES TO FOLLOW SOON