Restoration of 5" gauge 0,6,0 tank loco

[Dougs]

Ok loads and loads of progress
The strip down continued it is a massive job way bigger than I had imagined

Started to remove the water pump

Almost totally forgot the brakes so removed them they had loads of linkages and ars

I thought initially they were just bars but the are sculpted


I stripped them down and removed all the paint I will reprint all the bars and rods but remake all the pins from stainless so they can remain un painted.
With the running boards removed its an ideal time to strip the old brush painted surface

Ready to reprint with spray enamel paint should be tougher and heat resistant


All the fixing take ages to remove I don't want to damage them so they got to be removed for safe keeping

Good job I have all the drawings or it will never go back together lol

The cylinders are removed and everything can be moved around more easily

The lubrication tank removed and it can be turned up side down

The axel box can be seen clearly in the horn guide

Now for an interesting photo if you look carefully you can see a small piece of steel under the axel box I think this is an effort to stop binding

Now all the wheels removed top view

Bottom view

Isometric view

Now I have got to get it all measured
TBC

[Mackrick]

Wow now that's some work to strip it down this far, it is really appreciated the time you are taking to photograph the strip down and not forgetting g the details in the text as well. Really looking forward to further updates...

[Sooty655]

It's daft question time.................

If the wheels are carried via sprung axle boxes, but the coupling rods are rigid across three axles, doesn't the deflection caused by any track unevenness transmit stress and bending loads directly to the coupling rods?

[Dougs]

Sooty Not daft at all you are definitely 100% correct! if all is machined precisely and there is no slack in the system, the first bump would cause a lockup, therefore there is quite a lot of give built in to account for it.

And the results are in 3 hours on the CMM and we have found the problem and a fix.
First off the good news the chassis is square with almost no twist 4um was the worst error in the axel twist shocking really
There are two errors the first one is not the cause of the binding, the mountings for the axles are not flat, the biggest error is 0.6mm so all the wheels won't touch the rails with the same pressure
The binding is as I suspected caused by "cranking" not where I expected it though the rear axel is spot on at 90.06 deg the front is just about ok at 90.127 deg but the center crank is 89.54 deg that relates to 0.2mm error in the rotation on that axle alone I checked the links and its almost got enough play to rotate freely so if I make the center bush eccentric by 0.2 mm the "slack" will centralise and allow free rotation with enough free play to account for bumpy rails.
Happy days

[Dan4th]

MY HEAD HURTS !

Danatsea4th

[Dougs]

That's exactly what I said when we were measuring it up never seen so much complicated maths being done soo quickly he told me is ok " it's all triangles" yeah right.

Got some more eye candy for PW
http://modelengineeringwebsite.com/Stanier_City_of_Coventry.html

[34053]

Got some more eye candy for PW
http://modelengineeringwebsite.com/Stanier_City_of_Coventry.html

You really are spoiling me now, Dougs. I am speechless and in total awe of these magnificent Locomotive 'models' (such an understatement). Thank you and please keep your Progress Reports and Pics coming; they are so interesting and educational.

PW

[Dougs]

This is where thing are going to slowdown considerably as I am now now in the machining and fabrication phase this may not be great for fast progress but is way more fun than just stripping it all down.
So first off I want to get the chassis sorted this means I need to get the horn blocks all level to make the wheels level.
From the data on the CMM I used Autocad to give me a machining plan of how much material I need to remove

Next I bolted the rails down on my milling machine soo glad I had the long table version now

My plan is to touch down on the surface and then measure down the cut distance I am only looking to get it within a tolerance of 0.05mm so should not be a problem.

TBC

[Dan4th]

Oh, yeah....

Piece of Cake

D.

[Mackrick]

Oh, yeah....

Piece of Cake

D.

I agree Mr D , Dougs Makes it sound easy doesn't he......

[RLN]

It is easy..............................if you know what you're doing and have the right tools, oh, and the experience and expertise.

[Dougs]

It is easy..............................if you know what you're doing and have the right tools, oh, and the experience and expertise.

Lol you are more right than you could ever know, I would say having the right tools is one of the things that actually makes it all much easier, doing the above job 'the old way' would take ages to set up and be almost impossible to measure accurately. If I took one handy tool out like the mill then I would have to hand file the errors which would then mean I would have to re measure so a job that took 5 hours total would turn into days of work.
I test fitted the wheels and its now spot on they all are at the same height so I will have a six wheel drive loco at last, next job will be to clean up the frame so I will be repainting the inner rails red and touching up the black on the outsides then before I can go any further I need to de corrode the wheels and probably repainting the spokes.

[Dan4th]

Just have to say how nice it is that you
don't mind us looking over your shoulder
while you're doing all this

And also that you don't mind us asking
questions and giving you a hard time
while you're trying to WORK !

ONWARD!

Danf.

[34053]

Just have to say how nice it is that you
don't mind us looking over your shoulder
while you're doing all this

And also that you don't mind us asking
questions and giving you a hard time
while you're trying to WORK !

ONWARD!

Danf.

.......and UPWARDS!

PW

[Mackrick]

Not sure it watching over his shoulder, with all the photos it's like being in the too stood next to him

[Dougs]

Finished the machining of the chassis
I forgot to out a picture of the process up.
the big guage on the front is the depth gauge first off I lowered the cutter down onto the surface very slowly when it touches it starts to scratch the surface I then zero the dial and wind the cutter down lower, I was taking about 0.12mm off on that picture.

Jobs going on aside from the main work are cleaning old paint from the nuts and bolts and transferring all the old drawings onto CAD (two reasons for this one so I can get some much needed practice in and two so I can save the old drawings and print off any that I need to use to fix stuff or remake parts)
TBC

[Mackrick]

Keyboard skills as well, I am impressed Dpugs....

[Dougs]

if only i could spell welll,
all the skills i have are learnt are at work over the years so its nothing extra ordananry i just enjoy keeping up now and again things like autocad move on so quickly my first exam on cad was version 11 in the 90's the started using the years as versions in 2000 and have been poping new ones out every 2-3 years so the latest version 2013 is hard to get to grips with so i tend to lag behind the 'propper' design guys and snag the older versions they dont use any more.
i like the autocad software as it makes drawing errors stand out like a sore thumb already found one on my very first sheet two diferent dimensions for the same hole on the frame rails.
no progress to report today as i ended up doing a little rocketry my son had been given a couple of rockets so we had to try it out i will try and video the next one it's quite cool

[Mackrick]

Can't stand autocad..... Tried but just couldn't get on with it.

[Aceyone]

This is getting to be a must- see thread

[Dougs]

Right from the ground up quite literally thanks to sooty for pointing out something that will help me out later when I test run the loco, are the test wheels flat well no far from it


Looks like I have another little job getting all the rollers level
Anyway the wheels are getting some much needed love
Before,


After there are some small paint chips I will touch these up later


The frame painting is coming on too just got some details to finish off (top and bottom of the frames)

Once this is complete I can the run a drill though the holes to clean the paint off and run a tap through to do the same to the threaded holes, then I can start the rebuild.

[34053]

Thanks Dougs. 'Slowly but Surely'

PW

[Dougs]

Small update frames are all painted up and the wheels are all levelled up I did a test fit and it's looking great one side is perfect and the other is very close
Machining the axel blocks on one wheel set that were out

Test fit of the wheels in the painted frames

Parallel bar testing the level of the wheels just push the bar forward on the wheels and all three should rotate and they do

TBC

[Dougs]

Lots and lots of progress although it does not look like it, things are on track (excuse the pun) to get things running spot on,
First off paint all cleaned off the holes and the rest of the wheels cleaned

One last wheel suspension to be painted


Meanwhile progress on the cad model I switched from 2D to 3D this will aid checking out the bottom end linkages and I can simulate track undulations to see how much play will be required to stop binding
The render of the cad model so far

The loco back on its wheels again and looking very good indeed


It's already better and runs round easily with the coupling rods on however I know there is an error which will take up all the spare slack which is no good so I am going to remove one of the gunmetal bushes and remake an eccentric one this should sort things out
TBC

[34053]

The 'bottom end' is looking really good now Dougs. All your precise work is really paying off. Looking forward, with interest, to your next Report.

PW