12 March 2024
Wadebridge 34007 Engineering Report
Cylinders
As recorded in my last report the Outside Cylinders have been tested and this had shown up a number of cracks. All three cylinders were delivered to Cast Iron Welding in Coalville and it was agreed with Cast Iron Welding that the middle cylinder would have weld repairs at a cost of around £5,300. It was also agreed that the best course of action for the outside cylinders was ‘stitching’ a cold process that avoids possible distortion. The week beginning 4th March, Cast Iron Welding reported that they had completed repairs and that subject to measurements being satisfactory; the cylinder could be shipped back to Heywood. On Monday 11th March Riley’s reported that the stitch repairs to the outside cylinders had been completed by the Contractor and so all three cylinders are available for refitting to the frames, subject to any additional machining.
Frames
Work has continued on the frames and stretchers with weld repairs where required, NDT Testing, new fitted bolts and rivets. Currently work is concentrated on repairs and fabrication to the front buffer beam area.
Steam Reverser
Work has continued on strip down and machining new parts for the steam reverser. There has been a short delay in machining parts due to staff sickness at Riley’s.
Driving Wheels
The old tyres have been removed and wheel centres have been turn in readiness for new tyre fitting. Also journals have been dealt with. As of w/e 8th March new tyres are in transit from South Africa.
No progress to date, however, having spoken to Greg McGill on Monday 11th March, it is still likely that the boiler will go straight to Riley’s new premises in Bury and work will commence there.
Tender
Following the visit from Recardo Rail to Ropley on the 8th February we have a much better understanding of the Assessment requirements for the new build Tender. If we are unable to provided test certificates or source documents for components we already have, we will at a minimum, need to include retesting and in some cases verification of material and processes used. I have started a spreadsheet with information provided by Dave Williams, attached, which will form the bases of our investigation and submission to Ricardo.
Now we have a Contract with MHR Ltd the Tender has been moved into the shed at Ropley and some work has started. This has included, removing and stripping the buffers and draw hook for inspection and testing, removing the incorrect lamp brackets from the rear of the Tender.
David Ford
21 May 2024
Welding the preheated inside cylinder block
8 January 2024
End of Year Engineering Report
Progress
At the end of September Wadebridge’s frames were moved into the Works at Heywood and good progress has been made in NDT testing, repairs to cracks and removal and repair where required to cross members and frame stretchers.
The wheels sets had been set up in the Wheel Lath for re-profiling, and as reported earlier, found to have excessive runout of over 3mm which is out of tolerance even for heritage railway use. As it was not possible to machine out this level of discrepancy a request was made by Email to the Board to authorise the replacement of the tyres. The additional cost is in the order of £12.2k for removal and machining and upwards of £25k for the tyres. Having spoken to Riley’s on 8th January, they confirm that they will be ordering tyres from South Africa and they should arrive in the UK in about 12 weeks time. The old tyres have been removed and machining of journals and rims has started.
The Middle Cylinder Valve Liner pattern and casting have been ordered and three new couplings have been delivered.
After a long delay the Outside Cylinders have been tested and this has shown up a number of cracks. All three cylinders have been delivered to Cast Iron Welding in Coalville and Mark will be visiting on Wednesday 10th January. I’m hopeful that I can update the Board on the 11th January on cost and timeframes. As good progress has been made on the Frames, Riley’s are keen to get the Cylinders returned to Heywood asap despite the long delay in getting the NDT testing completed.
Riley’s have started a system of record keeping that should put us in a good position when we submit are documents to Ricardo for assessment.
David Ford
Project Manager
2 March 2024