PROJECT 62 - Overhaul News Page - 30075
30075 and 30076 were both moved to Shillingstone in January 2016 and, after much preparation work, the overhaul of 30075 started in May 2016. Meantime, 30076 has received a conserving cosmetic overhaul for display as a static exhibit. It is planned to keep the general public, as well as Project 62 Members, informed about the progress of the overhaul of 30075 via this web page. With teams working most weekends and Wednesdays, news will be posted here with photos on a monthly basis.
To volunteer to assist please contact James Frigot (Locomotive Liaison Officer) by email: email@example.com .
If you are able to assist financially with the overhaul costs, estimated to be around £50,000 we would also like to hear from you. Email: firstname.lastname@example.org if you can help with financial support or fund raising.
Shares are also still available if you would like to become a part owner of your very own steam locomotives. Follow this link for more information - SHARE SCHEME
Volunteers - please send work updates with photos as applicable by email using THIS LINK. Please try to keep image file sizes smaller than 150kB.
Work on both site by the Shillingstone volunteers and on 30075 by the weeekend and Wednesday Gangs has continued during May. Project 62 Members also turned out in force for a well attended AGM with buffet after. Photos above show newly laid ballast extending from the Station towards Sturminster Newton (left), work to bring the surface of the Blandford direction platform to standard (centre) and Project 62 Locomotive Liaison Officer - James Frigot - beside the chassis of 30075 alongside Shillingstone "Box" (photos courtesy of Pete Renaut and Bob Bunyar).
Also over this period, Locomotive Liaison Officer James Frigot has been inspecting the motion and assessing for work required as part of the current overhaul. His view is that the mechanical motion elements are suitable for use as they stand, with future attention such as remetalling bearings being conducted as required once 30075 is returned to service. However, he notes that the cylinders require attention, needing at the minimum a re-bore, but potentially the possibility of liners having to be added. In addition, it has been found that the right hand piston head has a severe crack which will require repair or replacement if this cannot be done. The valve liners were found to be in good condition, however, the valves will most likely require new rings. An independent examiner will be asked to carry out an assessment and give advice on these issues in the near future. If anyone does have any experience, or can give assistance on these matters, James would be only too pleased to hear from you and contact can be made via his email: email@example.com .
The Shillingstone Project team have been undertaking much work on site such as extending and resurfacing the car parking area, further developing the Permanent Way at the Sturminster Newton end of the site adjacent to the Signal Box and 30075's frames. The Project 62 gangs have been involved in securing the contents of the workshop container in preparation for its relocation around 50 yards up the site in the Sturminster direction. This occurred during April. Meantime further work on small parts and painting has been ongoing. Photos by Pete Renaut.
Despite some rather variable weather, both Weekend and Wednesday gangs have continued with work on the chassis, cab and component parts of 30075. Here, in the photo to the left, Barry Joplin and John Coulbert apply primer to one of the two sand domes that sit on top of the boiler. Photo centre shows Barry discussing the state of play with Howard Fry. 30075's chassis has been moved towards the Station platform area whilst the Shillingstone Station Project teams lay track through the area to form a run round loop at the Sturminster end of the site. In the photo to the right, Howard is applying filler to the coal bunker sides to eventually sand back and prepare for priming. The axle boxes have also been cleaned out and lubricated, the ashpan assessed for weld repairs to make sound and the water tanks checked and primed.
Whilst the work gangs continue with 30075 at Shillingstone Station, progress on the locomotive boiler at Vincent Engineering in Henstridge has also been positive. The photos above show where the thinned left and right side plating has been cut away from the inner firebox revealing the water space and foundation ring. The centre photo shows that the old smoke tubes have been removed from the boiler barrel. The view though the firebox tube plate looks through the boiler barrel to the smokebox tube plate at the far end. Assessment of the firebox tube plate shows it to be within tolerance for a further 10 years use. The smokebox tube plate was replaced on last major overhaul in 2004 and is likewise serviceable for a further "ticket". The photo right shows the firebox crown plate and stay ends, with a view again towards the smokebox through the firebox tube plate. Next work in progress is to make up templates for the firebox plate requiring replacement, weld new plate in place, make new stays and refit. Refurbishment of wasted areas of the foundation ring will also be required before the lower plate areas can be rivetted in place. Photos courtesy of Pete Renaut.
October and November have seen developments at Shillingstone where the Station has now been double tracked through the platform - see photo above left. 30075's chassis has been moved towards the Station so that the turn-out required to form the run round loop at the Sturminster end of the site can be instated (centre photo). Meantime work has continued to clean off old paint from the panels and parts such as the steam and sander domes and to prime them for eventual top coating. Howard Fry and Barry Joplin are seen in the workshop in the photo above right. Photos courtesy of Pete Renaut.
September saw further work to prepare 30075's valve and power cylinders for inspection. Removal of the frame side cylinder cowels revealed an accumulation of approximately two inches of thick greasy ash, topped by an inch or so of water (left photo). It is believeed that this is the first time these covers have been removed for some 25 years. Clearing the water and very sticky ash (centre photo) revealed that the grease trapped in the ash had in fact acted as a perfect preservative on the top cylinder casting surfaces (right photo). Initial external inspection revealed no apparent cracking in the outer parts of the cylinder castings, inspection of the insides is to follow.
In addition to this work, the motion has been cleaned over and all lubrication covers replaced with plastic/rubber grommets and plugs. This is so that easy access is available to additionally check condition of the "tails" inside the lubrication points (tails are bristle coated fine wires that assist with dispersion of oil from the oil pots to the motion itself). Any that are life expired will be replaced.
Attention in July and August moved to 30075's motion and boiler. Preliminary steps to check the valve and power pistons and bores started by removing the outer covers and insulation from the cylinder blocks (three photos top row above). Work has started to remove the cylinder heads by firstly freeing and lubricating the cylinder head nuts to ease future work (second row above, photo left). In the meantime, Vincent Engineering of Henstridge have been making progress with 30075's boiler. The three areas of thinned inner firebox plate (one on each side and one above the fire hole) have been cut out and the foundation ring rivets likewise removed from the affected areas. The centre photo, bottom row above, shows the plate removed from the inner firebox fireman's side facing forward . Next job is to remove the stays from those areas remaining in the outer plate and then to remove the smoke tubes from the boiler barrel. During August we also prepared for the Great Dorset Steam Fair where we shared a stand with the Shillingstone Station Project. The final photo shows Dave Wallis on the Bank Holiday Monday manning our bottle stall "Tombola" which proved popular with passing visitors!
June was a fairly quiet month with a number of volunteers taking a break for holidays. Conservation work on 30076 (photo left) took place, which also smartened the locomotive for the forthcoming summer school holiday visitor season. The Shillingstone volunteers have been active laying track into the platform opposite the main Station building (centre photo). The Wednesday Gang of Barry Joplin, Dave Wallis, John Coulbert and David Searle take a well earned lunchtime break in the warm weather with some "Start of Summer" hot dogs!
May 2018 - Part 1
Following work to release all bunker fixings and freeing the handbrake to bunker mountings 30075's bunker was lifted clear of the chassis on 9th May. The first five images in this selection of photos shows the chassis prior to the lift, the bunker being lifted clear of the frames and being lowered to site behind the cab which was removed at the end of January. The last four pictures show Dave Wallis and Barry Joplin clearing debris accumulated under the bunker over many years use, Dave starting the cab floor plate removal process by grinding off the fixing bolts and finally 30075's chassis by the Shillingstone signal box. The Signalman will find a new view of the Dorset countryside now the bunker no longer obstructs the view from the 'box! Our thanks are extended to Shillingstone staff, particularly Terry England for driving the digger and lifting the bunker, Geoff Baker for site arrangements and acting as "Lookout" during the lift and to John Drew for briefing Terry on requirements beforehand.
May 2018 - Part 2
Once the bunker was clear of the frames, attention moved to the cab floor plate. After unbolting the driver and fireman's side upper platforms these were stropped for lifting away (first photo with Howard Fry in attendence) both platforms were removed (centre) and the cab steps on both sides released and removed from the remaining floor plate (photo right).
Preparations to lift the bunker continued during April. Left photo shows Howard Fry releasing the rear bunker to frame bolts. Jan White (inside the bunker) holds the handbrake mount to bunker bolts steady whilst Dave Wallis undoes the nuts on the cab side (centre photo). In the photo to the right, Barry Joplin uses the angle grider to cut off a stubborn bolt holding the cab steps to the floor plate. By the end of the month all the bunker and handbrake mount retaining bolts had been removed, greased and refitted for easy removal when the bunker is lifted off early May. Once the bunker is removed this will enable access to unbolt and lift the cab floor away from the frames.
The weather in March, particularly the snow associated with the "Beast from the East", has not been a great for working outside. At the end of March the Wednesday Gang assessed the condition of the bunker and cab floor of 30075 and have drawn up a plan to remove these from the frames for refurbishment. Wednesday volunteer Dave Wallis is seen here photographing the rear bunker to frame fixing bolts for recording purposes (left photo), whilst the image taken showing the bunker lower edge to frame attachment, is in the centre. Despite the poor weather, further conservation of 30076 has occurred and the locomotive now sports a new bright red coat of paint on its front and rear buffers (photo to right).
With the cab and boiler lifted from the chassis of 30075, volunteers are now able to access the frames and motion components to clean down and assess work required to refurbish. These photos show the rolling chassis of 30075 alongside the signal box at Shillingstone Station with the cab in front of the chassis (left) and Howard Fry cleaning off accumulated dirt, oil and grease from the frames (centre). Meantime on 11th February as part of the 70th Anniversary of the formation of nationalised British Railways from the "Big Four" (Southern, LMS, LNER and GWR) the chimney of 30076 shows wisps of smoke to bring the event to life.
The culmination of all the preparation work on the cab and boiler fittings occurred on 31st January 2018 when the cab and boiler of 30075 were lifted from the locomotive's frames. The photos above (courtesy of Jon Collington, Pete Renaut and Project 62) show 30075 at the start of the day, followed by preparation and lifting of the cab to enable full access to lift the boiler clear of the frames. The second row of photos also show the boiler lifted just clear of the frames (beneath with the blast pipe clearly visible). The third row details the boiler being swung over the low loader. After sitting the boiler on sleepers and chaining it firmly, the bottom row of photos shows the loader departing via the tight access to the Shillingstone Station site. Meantime Project 62 volunteers Howard Fry and Barry Joplin secured the chassis, having lubricated moving parts and covered any areas where water can get into the mechanics (note the upturned steel bucket covering the blast pipe for example!). The final photo shows the front of the crane used for the lifts - the strap line "No Problem" pretty much sums up the day. Rileys are quite familiar with lifting 30075's boiler, having done so to install the boiler when last overhauled at the East Somerset Railway in 2004.
With the contract now placed with Vincent Engineering of Henstridge to have the boiler of 30075 lifted, taken to workshop and repaired to obtain a 10 year insurance "ticket" , the Wednesday Gang removed the final fixed window in the cab which is now ready to lift off the frames. With December and Christmas on its way, 30076 had tinsel and baubles applied to make a seasonal welcome to visitors as they enter Shillingstone Station. Having done this, the Wednesday Gang (Howard Fry, John Coulbert, Pete Renaut, Barry Joplin and Richard White (behind trhe camera!) enjoyed a buffet lunch to celebrate work done this year and to wish each other a Merry Christmas - albeit it somewhat in advance!
Whilst discussions to finalise contracts for the boiler overhaul were undertaken, both Sunday and Wednesday work gangs made final preparations to free the cab for removal so the boiler can be lifted from the frames. Here Howard Fry is removing the cab side windows so they are not damaged if the cab flexes during the lifting process. These windows, kindly donated by a Project 62 member many years ago, were once fitted to unrebuilt Bulleid light Pacifics. When rebuilt at Eastleigh works in the 1950's, many of the cab windows ended up as cloches in local allotments - which is where our windows were recovered from!
September has produced fruitful discussions with a number of boilersmiths, one of whom will be selected shortly to conduct the inner firebox plate repairs, refurbish the boiler and retube it to bring it to the standard required for the 10 year insurance certification that 30075 requires. The cab is ready to lift off, so the boiler can be accessed to lift it out of the frames and to despatch to the overhauler's premises sometime end November/December. Meantime the Wednesday Gang of John Coulbert, Howard Fry and Barry Joplin (in left photo) has continued cleaning and storing small parts. 30076 has received conservation for winter with the application of "Williams Formula 1" fluid to clean the paintwork, plus a coat of oil to the smokebox to protect the steel surfaces (right photo, again with John, Barry and Howard).
Further work to release the cab and boiler from the frames means that the cab and boiler are virtually ready to lift. A visual and ultrasound boiler repair inspection took place in mid August which revealed that 30075's boiler is in generally good order. The smoke box tube plate (replaced on last heavy overhaul 1998-2004) and the firebox tube plate were likewise found to be in good order. As anticipated, some plate replacement to the inner firebox sides below the brick arch area and a small patch above the fire hole is required. The first two pictures above show the water spaces round the inner and outer firebox wrapper and detail of the crown stay threads which are sharp. As with the other stays in the boiler, little if any "necking" is visible. The second two photos show the inner firebox side areas which have thinned under the brick arch position and require replacing. The last two pictures show the throat plate from the outer side, the numbers indicate the plate thickness in these areas.
June saw intensive work by both the weekend and Wednesday gangs which has yielded great results. The cab has been disconnected from the frames, with the exception of a few bolts to keep it stabilised and in place. Cross braces have been fitted to ensure the cab does not flex excessively and retains its shape when lifted (see left photo above). The Wednesday gang completed the firebox tube end grinding. All 150 tubes are now detached from their welds (photo to right above) and are ready for the next process of collapsing the ends in order to free them for removal.
The Wednesday Gang has been joined by new volunteers David Searle plus Barry Joplin assisting with the tube end weld grinding work on 30075. With one of, or both, Howard Fry and Barry Joplin covering almost all Wednesday sessions, it has been possible to accelerate work on the firebox tube end grinding. As of 24th May, some 98 of the 150 tube ends have now been freed. The first photo above shows Barry inside the firebox illuminating the completed tube ends which show up a bright silver colour. Meantime the Sunday Gang has continued with freeing and releasing the cab to floor and bunker bolts in preparation for the anticipated lift of the cab. This will then allow the boiler to be released from the frames for despatch to a third party overhaul facility. The second photo shows the centre boiler to frame support saddle which has had all its bolts loosened/removed in preparation for the lift. All smokebox saddle bolts can be seen to have been removed in the third photo.
Work has continued with removal of cab fittings. The manifold and remaining cladding/insulation over the firebox within the cab has now been removed. Work has continued grinding off the tube end welds inside the firebox - Howard approaches the 20th tube end to be ground off (of a total of 150 to be done) and a general view of track bed work in the Station where track recently recovered from a quarry near Salisbury by the Shillingstone Project will eventually be laid.
Work continues in the cab removing fittings in preparation to lift the cab from the frames, the manifold has been stripped of most of the associated control valves as seen in the picture above left. The centre photo shows the ends of the 150 smoke tubes at the firebox end of the boiler, each these tubes will be replaced as part of the overhaul. Project 62 volunteer Howard Fry is seen grinding off the tube end welds which secure the tubes in place in the picture on the right.
Work in the New Year has seen further removal of cab fittings in preparation to lft the cab. Photos (top row) show the fire hole with door now removed, the inside of the firebox with the brick arch removed (in preparation to commence grinding off the tube ends) and the driver's side of the cab with the vacuum and steam brake controls removed. The lower row of photos shows the firebox cladding area where the sander controls were mounted, the middle shot is of Tom Homewood removing the injector steam contol valves on the fireman's side of the cab and finally Dave Brown using some heat to help loosen the large nut holding the steam pipe union to the turbo-generator.
Most of the pipework connecting the steam manifold to associated equipment has been removed as well as the steam and vacuum pipes from the brake system. Drain pipes have also been removed and all are now undergoing cleaning and assessment for re-use where appropriate. Preparations to lift the cab off the locomotive are underway and, once clear, we will be able to assess the best method to lift the boiler off the locomotive frames - it is hoped sometime early 2017. In preparation for December Christmas Events 30076 has been given a tinsel and bauble "make-over" - she looks very festive as the first display you see on entering the site. The Shillingstone Railway Project has also been active in acquiring rail infrastructure over this period - rail that will eventually form the running line for Yankee Tanks 30075 and 30076.
During October further boiler and firebox cladding was removed. Fittings in the cab such as the reverser lever and mount plus the drain cock controls were also removed, along with associated linkages. Strip down of the steam manifold in the cab and removal of brake gauges also occurred. We now have an increasing number of parts off 30075 - large and small - that require cleaning, refurbishing and or painting. Please contact us via our Locomotive Liaison Officer Dave Brown by email: firstname.lastname@example.org if you are able to assist with this part of our work.
Work continued in September to prepare and remove the boiler cladding and insulation between the boiler and the cladding. Photos show 30075 with the first section of cladding and insulation removed on the section behind the smokebox, with Project 62 volunteers Tim and James releasing the banding securing the centre section in place. The centre photo shows volunteers Richard and James releasing the centre cladding section as it is lifted away and finally James and Richard again lowering the cladding section for storage prior to refurbishing.
Whilst one gang worked to remove the boiler cladding, a second team (Ian and Keith - first photo with Project 62 Locomotive Liaison Officer Dave Brown in the second photo) worked in the cab to remove the firebox fittings such as the gauge glasses and regulator control handle. A start was then made on removing the cladding from the firebox as detailed in the third photo.
Volunteers James, Wayne, Dave, Tim and Ian enjoy the sun at the end of a good day's work!
The remaining wooden cab floor sections on the fireman and driver's plinths were removed to reveal the cab to steel floor plate retaining bolts in those sections. The cab to floor retaining nuts and bolts were cleaned off, lubricated and slackened - along with the cab side to roof retaining nuts. Further work to clear the boiler of fittings occurred with the removal of the clack valves and associated pipework, which had been revealed following the removal of the water tanks in July. The boiler to frame retaining strap at the firebox end of the boiler was also removed.
Work continued to lubricate and slacken nuts and bolts to prepare for dismantling external boiler fittings and cladding and emptying items such as the sand boxes. By mid month the two sand boxes and steam dome cover were removed.
The final weekend of July saw the two water tanks taken off, following removal of the front access steps from the buffer beam to the tank tops. 30075 is effectively no longer complete for display purposes and is now attracting much interest from the public who now have overhaul activity to watch and photograph.
Following preparations in the smoke box, the two steam pipes were removed.
As the wooden decking on the main part of the cab floor was in poor condition, this was also removed. The steel plate of the cab floor was found to be in excellent condition with much evidence of the red lead primer having done its job over the last 12 years!
The real physical work of the overhaul has started with the inside of the smokebox being cleared of years of soot and rust beneath. Removal of the concrete sealant at the base of the blast pipe and preparation to remove the two steam pipes has been undertaken. Work will be ongoing to remove all boiler fittings, water tanks and cladding with a view to lifting the boiler so that the frames and motion can be worked on later.
January to April 2016
Following transport of 30075 and 30076 to Shillingstone on 20th January, initial conservation work was undertaken. The locomotives were moved into position for initial display and showing at the "50th Anniversary of the Closure of the Somerset & Dorset Railway" commemoration event held over the weekend of 5th to 6th March. 30075 received liberal coatings of oil/paraffin to shine up her now somewhat faded BR Black livery, this also started the process of lubricating all the external fixtures scheduled for removal during the strip down process. After stabilising 30076's finish, removing loose and flaking paint, this locomotive received a coat of black paint to conserve and also a BR logo, cabside number "30076" and tape "lining out" improve the look of the engine for visitor interest and to give an impression of things to come!
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Updated 31st May 2019