35006 Progress Report, March 2005
by John McMillan, 16th March 2005

The centre of attention this quarter has continued to be the boiler and firebox cladding, and this is likely to be the case for some time to come. The large firebox sheets, fitted earlier, have been removed for finishing and painting. The washout plug surrounds, previously tack-welded to the main sheets, have now been smoothed carefully into shape and are ready to be drilled for receiving the copper rivets to secure them permanently in place. After riveting, they’ll be painted (again) and the sheets will be positioned on the loco so we can continue to make up the numerous smaller cladding sheets that fit next to the larger ones.

View along the top of P&O. This is where the action will be taking place this year, with manufacture of the firebox cladding well under way. © 35006 Loco Society

The job of making the boiler cladding is one of apparent “one step forward, two steps back”, as sheets are made up, fitted, adjusted, removed and fitted again, and the exercise requires both great skill and patience, but we’ll get there in the end.

The old steam manifold pipe is beyond repair, but has been retrieved from the “not to be scrapped just yet” pile for one last moment of glory. It has been hoisted into position on top of the firebox where it has been invaluable as a template for the new cladding. The pipe terminates in a 90-degree bend, and slopes down from the cab to the steam manifold shut-off valve. Three small but complex cladding pieces have been made, together with the surround for the safety valves. Another challenging part is the cover for the steam manifold shutoff, which is shaped something like an elongated quarter of a sphere. Study of the same piece on 35028 “Clan Line” revealed that it had been made from a number of tapering sections welded together, giving the appearance of an Armadillo. It has certainly tested the skills of our sheet-metal worker and, once finished, we’re not sure who was more pleased with the result, him or us!

The long job of making the washout plug surrounds for the boiler back-head has been finished. They’re a cosmetic detail that some loco owners don’t bother with, but they’ll give the footplate a better ‘finished’ look.

Elsewhere on the loco, we found that the cylinder casings weren’t fully de-rusted when the loco was in bits all those years ago, and we need to complete the job before the cladding goes on for the last time. They are being needle-gunned before treatment with an exotic zinc- rich paint that gives a level of protection akin to galvanising. The cylinders are very prone to corrosion as there’s often high temperatures and hot water to wash away any protection.

Whilst it is a bit disappointing to see earlier fitted parts being removed from the loco again to obtain access for other work, doing so gives a chance to check on the ‘weathering’ of components, and we have found early signs of rusting on the running boards taken down from above the cylinders. We will take the opportunity to give both sides the full painting treatment, so we shouldn’t have to disturb them again, once refitted.

Progress in the machine shop has been hampered by the break down of our trusty Huron milling machine. Repairs could well be expensive, and we await the diagnosis of a friendly expert who is very familiar with our type of machine. Meanwhile we will continue with tasks that can be undertaken on other machines.

Finally, we’ve taken delivery of a spare set of brake blocks for the loco, as we had been told that the equipment used for their manufacture was to be sold abroad. At least we’ll be set up for some time before having to chase around the globe looking for replacements!