The Restoration Story
The loco has been under the Trust's ownership since 2016 and this page provides a timeline for each year of restoration.
Most of our volunteer's efforts at the start of the year must necessarily be devoted to the winter maintenance tasks on working locomotives so there is a limit to what we are able to do. However, our contractors at Roach Engineering are progressing our new drag box. The photo shows it part machined - it is now finished and awaiting delivery to Toddington As you can see, its a big chunk of metal! It will be really good to get this in place on the loco.
We have also made some more progress with the "rivetting" project - the new footplating we have made needs lots of holes drilled to match the existing fixing points. We have acquired a set of heavy duty, centre point punches - we choose the right size for the existing holes in the framework (and they are far from all the same size!), quick tap on the punch through the existing hole and mark the new platework then get to work with the mag drill. Sorry there are no photos of this work in progress as I was too busy with the drill to take any - will do better next time.
Now we have the funds (thanks to you, our supporters) for the new smoke box, we are getting quotes for the next stage - this will be the purchase of the door ring and the door itself. We have bought a new "curve mag drill" which will be invaluable in drilling the many holes both for the door end and for attachment to the boiler in due course.
In the machine shop at Toddington, our eccentric straps have been completed - a next stage is to have the eccentrics themselves machined. To progress this we have acquired a "dummy axle" that will be used to mount the eccentrics in the machine shop and get them true. Then will come the application of the bearing surface of white metal - to get ready for this stage we have sourced 50kg of (very expensive) ingots of the metal. Fortunately, the material machined off can be recycled.
The new rear eccentric straps matched with the existing parts - all the bolts that hold them together had to be made to match.
Metal restoration has played a large part in our work to date - hardly surprising considering the many years in the open since withdrawal in 1963!
The reverser frame is largely in good condition but wioth some localised corrosion where the damp coal dust accumulated under the cab floor - here it is when still attached to the rusting floor
The frame was removed and the rusted section cut out.
A new piece was ordered and then carefully cut to the exact size to match - we cut the corroded sections well back to get a really solid repair. The edges were then shaped to allow a good weld to made - here we are ready clamped up for the welder.
2021
We have put together a gallery of images to illustrate some of our work over the year (in case you don't have time to read the full article!
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New frame stretcher – ready for riveting in place.
Badly corroded steelwork.
New replacement pieces being fabricated.
The new pieces clamped in place – ready for welding then the whole section will be riveted in place – once this is secure, the old buffer beam can be removed and the new one riveted. Below the new section, the drag box can be seen – this will also be replaced as part of the riveting exercise.
Here can be seen some sections of new footplating - as the frames are not quite "square" anymore (due to years of wear and tear) some trimming is needed then drilling will be needed to match the rivet holes in the supporting frames - then we can rivet the platework into place.
We did find one of the arms that supports the outer frame in position had a major problem - Like many of these components, it had been repaired during its BR service days but not very well! The piece was removed - it had been welded on as well as riveted - and can be seen below with the detached end plate.
and below is the repaired section ready for re-riveting into place
Work has been undertaken on the horns in preparation for the horn grinding - here is Dave at work with the rotary wire brush and the finished surface
Pitting can be seen on the cleaned surface - the horn grinding will result in a perfectly flat section - measuments have shown that even when ground, we can have years of service from these components.
Work has also been underway on our axle boxes - these have all been thoroughly cleaned prior to refurbishment. Unfortunately, during the years in storage four of the axlebox underkeeps have been removed and most likley used on other locomotives - we have ordered four new castings which were delivered in the Autumn - these will then need some machining before being ready to fit. The wooden pattern for the castings are pictured - looks complicated but the foundry seem to understand whats was needed
!
The new castings went on display at the november Gala
The top covers of the axleboxes have badly corroded and require replacement - 8 new ones have been made (two pictured below). These now require drilling to match the individual boxes.
And from the machine shop - refurbished brake hangers
A batch of clack valves - one finished and lots of components for the rest - at the back of the photo csn be seen the brass bar that the valve parts were turned from
To allow restoration work on the timing mechanism of the loco, a number of the components must be removed (carefully!) before they're can be overhauled. One of the rocker arms has proved very stubborn and has resisted the efforts of copper hammers, oxy-acetelyne torchs and a hydraulic press - part of the problem being the difficulty in applying the ram of the press. To solve the issue, a former has been made to fit over a bracket on the frames - this will allow the full pressure from the hydraulic ram to be applied - hopefully it will now come apart. The specialy made former is pictured below
Here is the chairman, in very pensive mood, operating the hydraulic press during one the earlier attempts to free the part
The cab roof was taken to Tyseley to be rolled into shape - pictured on its return with the original framework angleiron.
Now fitted to the cab and the whole trial mounted into position
2020
The eccentric straps have progressed but there is still some way to go before these are completed
Axle boxes all cleaned ready for refurbishment
The accomodation bogies were assembled and painted - the wheels came as castings and needed machining for axles and greasing points
Help came from the Lottery Heritage Fund with a grant for additional small tools (to reduce sharing) and lots of PPE to ensure we could make progress as soon as some restrictions were lifted
This time its Tina in full protective equipment prior to using the angle grinder - these rivets will not give up without a real fight!
Work continued to remove the rear buffer beam and frame stretcher in preparation for new steelwork being riveted in place - here Andrew is drilling a pilot hole before using the mag drill (seen in position behind him) to remove the old rivets
The finished valve bore - this was liberally coated with petroleum jelly and wooden covers fitted to ensure no deterioration
The equipmemt itself is "heritage" having been rescued from a BR workshop
The valve chest boring was completed under the supervision of contractors from Tyseley Loco Works - Stuart can be seen setting up the equipment
Work on the wheelsets was completed at South Devon Engineering - here the old tyres are being removed prior to fitting the new ones:
Painting next - the sets received 2 coats of anti-corrosive primer, 3 coats undercoat, 3 coats black gloss - and the machined parts were liberally coated in waxoyl and denso tape to ensure no rusting before we are ready to rewheel
The wheelsets arrive back at Toddington from South Devon


New Tyres on – the process is reversed to fit the new one – the tyre is heated and then the wheel centre dropped in – cooling and contraction makes a snug fit then a retaining system (the Gibson Ring) is fitted to make completely secure.
2019






2018



2017

Pair of expansion links acquired – nearly new and surplus to another owning group’s requirements – half the price of new.
Non-destructive testing of the boiler undertaken - to establish detailed restoration requirements and where platework needs to be replaced. We are already aware that the lower firebox outer steel platework, some doorplate and throatplate will have to be replaced but no further unwelcome news.
2016
The Restoration Story begins, but to start you have to take everything apart!


Smoke box removed – badly corroded and not re-usable, but the chimney was salvaged.


