Here are the diary entries for this month. You can use the forward and backward links to see the next or previous months. Most photos taken before 2018 are small size. From 2018 onwards, most photos you see below will have a link to a full size image by clicking on the photo.
Instead of cold riveting, we are assembling the frames using fitted bolts - see the design page for an explanation. Each bolt is supplied 10 thousands of an inch oversize in diameter and all of the frame holes are currently undersize. The holes are drilled and reamed to size and the bolts are machined down to each individual hole to give an interference fit. This is going to be a considerable job during frame assembly. Today, we retrieved all of the fasteners from the stores and have started to create work packages of fasteners that match the assembly instructions. The bolts are in the white bags on the stands and the nuts are in the orange boxes on the left hand stand. Left to right, Geoff Turner, Keith Greenhow and Alan Marshall
Cast Stretchers update.
Work on the machining of the three lower cast frame stretchers is nearing an end, two have been completed with the third stretcher only requiring a few hours work before a final dimensional check can be carried out upon it. As soon as the final stretcher has been passed off then the erection work of the main frames can start in earnest. These three lower cast stretchers are large components and also very complex in the number of machined surfaces on each one, the middle and rear stretchers weigh approximately 500kg each. The attached photo of the completed Rear Stretcher shows some of the detail closer up, including the Spring Hangers, please note for ease of storage on the pallet the stretcher is upside down. As our usual Monday work party left CTL Seal yesterday the Main Frame plates had been moved into position in the Erecting Shop in readiness for the main erecting build work to commence.
Frame Assembly Starts
A major milestone has been hit this week as the frame assembly work has started. The main frames have been laid out on trestles as you can see in the photo. A chamfer has been ground on the inside lower edge of the frames as specified in the British Railways drawings. This will allow the cast steel stretchers to fit tightly to the inside of the frames. The first 3 vertical stretchers have been prepared by removing the protective paint from the flanges as we need a metal to metal contact on all connecting faces. The right hand stretcher is the intermediate boiler carrier. The current plan is that initial asssembly is with the main frame plates horizontal as shown. Once a number of stretchers have been fitted, the frames will be rotated through 90 degrees and lowered onto the cast steel strechers.
A challenging area in frame assembly is at the rear of the main frames. Here a complex fastener pattern joins the main frames, the frame extensions, the front firebox support/pony truck pivot and the feet for the trailing axle keep. Here members from the Clan Project Engineering team discuss the best method of assembly with the CTL Seal assembly team.