13 - 16 March 2010
Saturday 13 th March
With the cab & B end body sections of D8233 due to be craned off in just two days time, today would be the day to complete all necessary preparations to detach the cab & B end body section from the loco frame and more importantly each other, previous working parties had completed the unbolting of the cab & B end nose sections all that was left now was to remove the seam welds around the B end pannier tops that attach the lower body section to the top section and the cab. These welds had proved very stubborn to remove before but this time around Jason & Jim had a cunning plan for busting open the cab bulkhead welds once and for all.
After pulling the tarp back Jim started but cutting out a section of the outer frame skin plate around the B end lower section that had been missed during previous weld cutting in this area before, he soon made short work of that and it was cut. Jason & Adam had to clear out the remaining cab parts that had been piled up in the cubical space, after that was done Jason & Jim inserted heavy duty hydraulic bottle & trolley jacks under the frames blocked out with suitable bit of wood and began to lift the B end up evenly on each side with the hope that the cab welds would shear, unfortunately they held firm so they were forced to utilise chisels and big hammers to start splitting the welds. With the pressure applied via the jacks this made the task a little easier, eventually after much hammering and chiselling both welds were separated but not with the bank we had hoped for, however when we tried to jack the two body section away from each other they still appeared to be attached, it was soon found that three bolts under the lip of the cubical well in the top section had been left in so these had to be removed, but when they were the B end body section was effectively free and could now be barred away from the cab to open up a gap.
By now it was lunch time so everyone stopped for food and after it was decided to have a go and separate the upper B end body section from the lower one and separate the longitudinal welds. At first we used angle grinders with the heavy duty grinding disc, this was getting results but it was painfully slow work, then Jim suggested that we try the Plasma cutter to cut through the pannier top plates that the frame was welded to. Agreeing to this idea and the plasma cutting equipment was set up and now that we know how to use this cutting machine properly it worked like a dream and Jim soon sliced through the plate on both sides and for the first time since D8233 was built the cubical section of the B end nose end was free and ready for lifting. With all the work required to detach the cab & B end now complete the guys all packed the tools away and pulled the tarp back over the loco all ready for the big lifts on Monday.
Monday 15 th March
With the lifting completed on D5705 and items loaded (see D5705 report) Alasdar then set up his wagon along side D8233. First to be lifted off was the middle and roof section of No2 end in one lump. This was slung and lifted into the car park. The next section was the bottom section and after some clearance and slinging issues this was lifted off D8233 and into the car park. We then hooked up the compressor and this was then lifted off and onto a pallet which would be moved into the Crossley tent later in the day.
Next up was the cab. Once slung, the weight was taken and with a twang the cab was free. Under the cab mounting runs a thin layer of cork gasket that was a bit reluctant to let go of what it had been next to since built! The cab was then manoeuvred upwards over some pipe work that was left behind and lowered down into the car park. With this Alasdar had to depart for a meeting, arrangements were made to meet him at the shot blasters in the early afternoon to unload the Co-bo's roof sections and then come back to load the cab and No2 end from D8233
Whilst Alasdar was gone opportunity was taken to have a spot of lunch and also resistance test the compressor motor, which was found to be in superb condition. So the compressor will only require minor work before being refitted later this year. Alasdar then contacted us to say he was en route to Radcliffe and so the away team set off for Radcliffe to meet him. Whilst away Phil Bailey from the ELR came round with the JCB and kindly moved the compressor into the back of the Crossley tent.
At the shot blasters, we met Alasdar and some very keen chaps hand lifted off the roof sections and placed them in their shot blast shed. Once unloaded we headed back to Baron st to load up the Cab and No 2 end onto Alasdar's wagon. First to be craned on was the cab, this was then strapped down and then the bottom section of No2 end was lifted on with the middle and roof section placed upon this. All was then strapped down and we set off for Radcliffe - it certainly felt a bit weird travelling behind the cab of D8233 on a main road!
Upon arrival at the shot blasters they had been busy making room so it would be easier to unload, Alasdar then set up and we first unloaded the No 2 end in 2 halves straight into the shot blast shed, then the cab was lifted off and straight into the shed. With all unloaded we headed back to Baron St. Whilst we were away Rob had begun on wiring the lights inside the Crossley tent and later in the afternoon we were able to fire up the genny and have the tent lit up. Jason made a start in sweeping off the years of dust & crud from around the cab and No 2 end floor area. But as we were heading into early evening, energies began to go low and we decided to call it a day. The tarp was brought back over D8233 and tied down for the night.
Tuesday 16 th March
With a little later start, We were on plan C for today; Plan A was to shunt the ex Irish thumper into position, Plan B was to sort out Paddy ready for turning into the Crossley store and workshop. But as work slightly overran yesterday Plan C was to carry on wiring the Crossley tent and continue prep work on D8233 for fitting the Generator in April.
Chris Tatton and Rob Mason carried on with wiring the tent and fitting lights, whilst Chris B and Jason worked on D8233. The flywheel that connects the cranks shaft to the generator was dug out of storage along with the nuts and bolts, these were then cleaned up and had rust removed. Jason then found a pole to prop up the trap where the No2 should be and utilising Robs van a couple of side doors and the exhauster pannier doors were transported down to the tent out of the way. The crankshaft flange was then cleaned up and the flywheel then offered up and the first bolt entered. All the bolts were then lightly tapped through and the nuts put on. In a torque order the nuts were then tightened up as much as could be by spanner. Using a modified ring key and long tube, with another tube stopping the flywheel from moving round, the nuts were then tightened up to the nearest castle hole to match the split pin hole in the bolt. The split pin was then entered and opened out, the flywheel was barred round to the next bolt and the process repeated. This work took up most of the morning. After lunch Chris and Rob had completed the tent wiring and lighting and we decided to get other stuff ready for lifting off when we come to refit the generator in April. The two big down pipes from the header tank to the water pumps were disconnected and freed off. In the cooler group, the two small bleed pipes that go to the header tank had the flexible removed then unscrewed from the header tank. The bolts for the main roof section were left in and will be removed once ready for lifting off on the day. The bolts and spacers for the two main handrails were dug out and the handrails were then lifted up in turn and the bolts entered and tightened up, this so we have something to sling from when lifting the roof section.
To finish off, Jason marked out where the main conduit lies, so when we fit the replacement we know exactly what position to put it.
With this done, we decided to call it a day and go home after a couple of very exhausting but productive days. The cab and No2 end are due to return from shot blasting and priming on the 23 rd March. The cab will be put into the tent for any repairs then painting inside and out.
The next working weekend is 3/4 April. If you wish to lend a hand please contact Chris Tatton
|Above : The saturday job was to cut the seam welds on the B end pannier tops. © C15PS|
|Above : On the Monday the cabs of both locos were uncovered. © C15PS|
|Above : The lower section was a tight squeeze to get out under the overhanging pole. © C15PS|
Above : Some hands on manoeuvring was needed to get the cab lift started off.. © C15PS
Above : D8233 looks weird now with the Cab and B end body sections removed.© C15PS
Above : Later the Truck came back to collect the body sections starting with the cab.© C15PS
|Above : With Alisdairs truck all loaded up it was ready to depart for the shot blasters. © C15PS|
|Above : all the body sections are now dropped off in the shot blasters building. © C15PS|
|Above : The tarp is pulled back over the empty void left by the missing body parts.© C15PS|
|Above : After re-fitting the central flywheel disc Chris Baily applys the split pins. © C15PS|
|Above : the loose Pannier & bodyside doors have been moved down to the tent. © C15PS|
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