Tag Archives: fabricated trailing truck

Crank Axle, Engineering Update

SUMMER 2023 ENGINEERING UPDATE

Summer Engineering Update

Welcome to this Summer 2023 engineering update from the General Steam Navigation project.  Progress has been made on various engineering fronts on the project over the past few months and with some of our background efforts about to bear fruit we’ll have some brilliant work to share over the coming months.

Boiler
Since the last packet, there has been no further progress on the boiler, but we are working on scheduling the boiler washout. This was originally planned for February, but was postponed due to a combination of personal circumstances.
Mother nature had a go at helping with the washout recently, but photos from inside the boiler show everything remains dry. The Boiler washout actually took place at the beginning of August with the grateful assistance of our friends within the Swindon  & Cricklade Railway  Steam loco department.  Details of the Boiler Inspectors preliminary inspection report will be in the next issue of our Members Magazine The Packet,  if you not already a member join here today to get the latest news first. 

Trailing Truck
Progress on the trailing truck has been slim since provided in the last Members Magazine The Packet, as the NNRE have had other tasks taking higher priority. Following the previous issue of The Packet, we have had some helpful insight into the weldability of gunmetal (and leaded gunmetal) which is proving very useful.

Crank Axle
Physical progress with the crank axle continues to be impacted by geopolitical events causing volatility in the price of steel, after discussions with our friends in the B17 Steam Locomotive Trust project & A1 Steam Locomotive Trust, with whom we were planning to place a group order for A4T forgings for the stub axles, we are pausing the ordering process until we have greater certainty over the price. Whilst it is disappointing to not be placing an order for these crucial parts of our locomotive, it feels more prudent to wait, saving us money in the long run. During this self-imposed delay, we continue to use the time to produce the engineering justification for manufacture of the stub axles in A4T & the sweep webs in 817m40, so that when we are happy with prices, we can proceed.
We are also continuing with the initial design of the new chain-driver sprocket to fit the balanced crank axle design. The design fitted to the original unbalanced crank won’t fit the balanced crank design, as the stub axles are wider & the mounting points were changed. There was a design for the sprocket for the balanced crank axle, but it is not in any drawing collection that we are aware of, and is assumed lost. The design we are working on will be based upon the original sprocket along with the mounting design for the eccentric fitted on rebuilding to drive the inner motion, as we know the mounting points were broadly the same.

Leading bogie
Work has started on taking off the removable parts of the bogie, to reduce the work that would be done when it is sent away. The key component is the side control unit.
Our leading bogie was attached to the frames via a pin and bush arrangement, similar to the trailing truck. On both of these, the pin is firmly attached to the frame of the locomotive, but the bush can slide laterally within the side control unit. Either side of the bush is a spring in compression. As the locomotive enters a curve, the frames will want to continue in a straight line, whilst the bogie will follow the curve. This will compress the spring on the outside of the curve, and extend that on the inside of the curve, helping to steer the front of the locomotive through the curve. We have started taking the side control unit apart, so it can begin to be cleaned & restored.

Frames
The main activity at recent working weekends, beyond the leading bogie, has been on the frames. As we will eventually need to remove all three cylinders from the frames as part of the process of replacing the middle one, we are starting to remove, clean and replace/refix all the nuts & bolts that hold the cylinders to the frames.
This will mean that when we are ready to remove the cylinders, we should be able to detach them quickly. It will take some time to do this, but will save time in the long run. The middle cylinder is being replaced, with a new one to be manufactured to the original design, with outside admission. Removing the outer ones will make removing the middle one easier, and will give us the opportunity to

This an extract of the full report that appears in the Members Magazine The Packet, if you not already a member join here today to get the latest fullest news first. 

Engineering Update

Winter Engineering Update

Work on General Steam Navigation has progressed at a pace over the last few months with our regular working parties at Blunsdon. The majority of the work has been focused around 35011s chassis in preparation for “crane day” that happened in November. With the help of our friends at the Swindon and Cricklade Railway steam department our volunteers were able to successfully remove the five frame hangers that won’t be required in the restoration of  General Steam Navigation back to Bulleid’s original condition.
These components were: the slidebar bracket hangers (these were heavily modified upon rebuilding due to the outside valve gear) and  outside motion brackets on each side; along with the screw reverser bracket on the left hand side.
In the spring of next year it is planned to remove 35011s remaining wheels and front bogie in order to enable a full assessment of her frames to be undertaken.

The newly removed components from GSN

Preparation work for producing the components required for the chassis and the alternations to the existing metalwork is being undertaken at the moment. This will enable the work to restore the rolling chassis to be only limited by the amount of money that can be raised to pay for the work. To help this work the Society has set up a “Putting Funds into  the Frames” appeal which enables people to donate as little or as much to the project with the guarantee that it’ll be spent on the frames.  You can find out more here.

The converted drawings now in CAD form that is required for an original condition Merchant Navy.

Supporters will be aware that when we lifted the boiler from the frames in October last year, we also lifted the rear of the frames to release the Trailing Truck. Since then, work has been undertaken to remove the majority of the components that make up the Trailing Truck.
Following an independent assessment, we undertook a competitive tender process and in August we awarded the contract for the full refurbishment, and certification of the Trailing Truck by specialist contractors North Norfolk Railway Engineering (NNE).The Trailing Truck left Blunsdon and arrived safely at NNE Weybourne on the 10th October.

The Trailing Truck at the North Norfolk Railway

Since then North Norfolk Engineering have provided the following update of their activities:

• Completed the dismantling of the main component parts, with the truck chassis now lifted off the wheelset in readiness for the complete set of main parts and wheelset being sent away for shot blasting.

• Undertaken a series of key dimensional measurements to assess the general condition and wear levels ahead of developing the engineering overhaul strategy.

• Removed the seized main pivot pin out from its bronze bush and assessed the reason for it seizing, as the bush appears has moved during its working life  and rotated in the frame boss, blanking off the grease hole in the process, reducing lubrication.

The next key stage is to undertake Ultrasonic Axle Testing (UAT) of the axle and the axle to wheel interfaces to verify that no flaws are present. It will be carried out by a Rail Industry approved axle specialist early in the new year (at the same time as the annual check of all locomotives on the North Norfolk Railway to minimise cost).We are in the process of arranging the purchasing new suspension coil springs and are currently working with various suppliers. To help fund the restoration of the trailing truck the Society is offering a maximum of 30 members the opportunity to purchase a ‘Lot’ for £500. Members are welcome to purchase as many ‘Lots’ as they wish up to the maximum target amount.

Members of the Fund Group would receive a number of benefits including:

  • Certificate of membership of the ‘Trailing Truck Transformers’
  • Name engraved on a suitable brass plaque attached to the refurbished Trailing Truck
  • Regular updates on the refurbishment of the Trailing Truck
  • An invitation to a VIP day at the Swindon and Cricklade Railway to see the completed Trailing Truck once it is returned to the railway.

For details on how to become a Trailing Truck Transformer please click here.

CME with students on Boscastle

In November our CME Dr Steve Rapley  took a group of students from Loughborough University to look at the smokebox and exhaust of 34039 Boscastle. This was to aid their understanding of the geometry they’re studying as part of developing the Internal Aerodynamics and draughting of 335011 General Steam Navigation Locomotive Restoration Society.  The Society would like thank Andy Morgan and Mike for hosting us.

You can find out more about previous projects undertaken with Loughborough and Birmingham Universities can be found here.

Progress continues with the boiler, there are still some stubborn ends of tubes to remove, but it is down to a handful now. Sterling work by our volunteers (including Paul G, David O, Geoff A & Jack G) continues with this strenuous task, with the expectation that the remainder will be out in the coming months. Work has started on removing rust from the inside of the firebox, and generally cleaning the inside of the boiler and firebox ahead of a planned inspection early next year. It may seem that one paragraph seems like little progress on the boiler, but this work is very labour intensive, and with only a small band of volunteers, maintaining Covid safe practices, it takes time for the fruit of their labours to become apparent.

Volunteer posing with the locomotive at Blunsdon

 

In order to keep moving forwards with our restoration activities, the society is looking for a qualified railway mechanical engineer, preferably with welding experience or weld design experience, to advise the CME & Engineering Sub-committee in this field. If you fit this description, or know someone who does, please get in touch with us via info@35011gsn.co.uk

The momentum being generated by our engineering team means 2022 is going to be a very important year for the project with some big goals in mind. To achieve this we will need your help, you are able to support us in many ways if you are not already a Society member you can sign up for membership for currently only £15 per year here, or donate to the Society here or even better become a shareholder here.

As always thank you for your continued support.

Crank Axle, Engineering Update, Other News, Trailing Truck Transformers

General Steam Navigation Locomotive Restoration Society awards contract for Trailing Truck restoration and confirm the grade of steel for new crank axle.

At the Annual General Meetings of the General Steam Navigation Locomotive Restoration Society (GSNLRS) and General Steam Navigation CIC we were delighted to announce that following the removal of the trailing truck from the frames in October 2020 and months of preparatory work by their hard working volunteers, that the restoration contract for the trailing truck has been awarded after a tender process to North Norfolk Railway Engineering.

Located at Weybourne Engineering works, North Norfolk Railway Engineering presented a strong bid for the work, with a high level of engineering detail, that respects the historical merit of the unique in preservation fabricated Merchant Navy trailing truck.

Originally fitted to a series 3 Merchant Navy, our fabricated trailing truck is the last survivor of its kind. Lighter than the cast truck fitted to the other preserved Merchant Navy locomotives, longer than a Light Pacific’s truck, the GSNLRS are having this unique piece of Bulleid locomotive design restored to mainline standard, a crucial step towards GSNLRS’s vision of an original Merchant Navy with original air smoothed casing and Bulleid’s patented chain driven valve gear.

Funding for the Trailing Truck restoration has been via our Trailing Truck Transformers Fund Club and ‘Lots’ being available for purchase to join the club. Membership of our Trailing Truck Transformer Fund Club is still available, for details click here.

For more information on the North Norfolk Railway go to: www.nnrailway.co.uk

Crank Axle Steel Selection

Since 1966, 35011 has been without it’s central crank axle. Alongside the missing valve gear, this has been the driving force behind the decision to return to original design condition, due to the cost of replacement to either design being similar.
After many years of behind-the-scenes research in the BPLA collection & National Archive in Kew, and recent detailed Finite Element Analysis conducted at the University of Birmingham, under the supervision of Professor Karl Dearn, has demonstrated that A4T steel is of a suitable grade for the correct balanced crank axle design for 35011 in original design condition.

The stress report of the balanced design maximum stress reduced by 23%

This means the GSNLRS can proceed to final design of the central axle & balancing of the motion, and the order placement for the steel in the coming months and moving the project further forwards to a functioning original Merchant Navy once more.
For more information on the University of Birmingham FEA Project outcomes  click  here:

These two announcements are major steps forward for the General Steam Navigation Restoration Society, for more information on how you can help support  the project click here.

Campaigns

35011 General Steam Navigation fund opened for the transportation and tyre profiling of the bogie and trailing truck wheelsets.

On 2nd October 2020, the boiler of Ex-SR Bulleid Merchant Navy Class, 35011 “General Steam Navigation” was successfully lifted from its frames for the first time since 1959 and the separation of the trailing truck from the frames. The General Steam Navigation Locomotive Restoration Society is now seeking funds to help overhaul the front bogie and trailing truck wheelsets.

35011 front bogie at Eastleigh Works 1959

It is  estimated that the trailing truck axle will be machined by a contractor off site in early 2021. This is where we need your help we are fundraising to help cover as much as the cost as possible with the target being set at £3,500.

The unique in preservation fabricated style trailing truck of 35011

Supporters can donate to the cause via the Society’s JustGiving page at https://www.justgiving.com/crowdfunding/gsnwheelset

Work on 35011 will now be directed to the restoration of the chassis, trailing truck and the front bogie and further fund-raising campaigns will be launched in due course.

You can help support us in many ways if you are not already a Society member you can sign up for membership for only £12 per year here, or donate to the Society here or even better join us as a shareholder here.

As always thank you for your continued support.