Kit 3 - Smokebox

ModelWorks 4 inch Scale Burrell Agricultural Traction Engine
I collected Kit 3 from my local City Link depot 10th January

The contents of kit 3 laid out for checking.

Modelworks have not included the small name ring because they are not happy with the quality.  I find this reassuring, the last thing I want is substandard lettering on the name ring.  I am sure the replacement will be worth the wait.

This is an enlarged shot of the large name ring.  I am happy with it as is and I don't think I will be polishing too much. 

The first step is to attach the chimney base to the smoke box.  Since the copper rivets are distorted using the rivet snap to be flush with the chimney base this step is irreversible. After a trial assembly I donned rubber gloves and applied plenty of foliac to the chimney base and offered it up to the smoke box.  The 4 copper rivet went in easy and I was surprised how easily it was to snap the rivets heads inline with the contours of the base.  

One problem I have noticed is that some of the rivet bolts for the smokebox door ring are oversize.  Checking them with the micrometer reveals a variation in size with some too big for the holes.  Eight of the bolts are 0.233", six 0.250", three 0.252" and one is 0.257".  These last four will not  fit!  The obvious solution would be to make the holes bigger but I would prefer to fix the route of the problem.  I am contemplating how to hold the bolts in the lathe so that I can take a shave off them.

I made this simple collect out of brass

Modelworks inform me that, as with any defective components, they are happy to supply  replacements. In my case it was quicker to fix the problem than pick up the phone.

Sunday

I trial assembled a few of the components and discovered that some of the holes do not line up perfectly. Since the undersize bolts won't fit they must be out by at least 10 thou.

I have resolved to check all parts before committing to further assembly.  If the holes are close I can drive the bolt in using the snap but I suspect some holes will need to be eased.  I don't want to discover this half way through when I have already driven in some of the bolts.   I am pondering using a 1/4 inch reamer.

I have just tried my 1/4 reamer in the holes and I am convinced they are 1/4.  The advantage of using a reamer is that I can use it even if I am half way fitting a component.  I hope it does not damage the reamer.

Tuesday
I have spent the last day or so mainly working on my POP wagon.  This is back in the engine shed so it is time to address the alignment issues.  My  biggest problem is the Perch bracket. The holes are out by about a millimetre.

 
This shows a close up of the perch bracket, fixed with one set of bolts on the other side.

ModelWorks apologised for the problem, and suggested that I open out the holes in the bracket to 7mm.  Since this is only a small increase in size the drill is likely to snatch I needed to find a way of clamping the bracket in the drilling machine.  Wish I hadn't painted it now!  Not having and adjustable angle plate I came up with this Heath Robinson arrangement.

Clamped in this fashion drilling out was very tame.  The set up for each hole was quite laborious so I tried one using a hand held electric drill, the drill jammed and generally misbehaved, suffice to say I went back to clamping in the drilling machine.

Wednesday
Having fixed my holes, I decided to assemble the major components.  The holes in the smoke box rig were not perfect but I was able to drive the rivets in with the snap. Well that what rivets are for and the odd dent in the head adds to the character of the model.

The smokebox door had very obvious turning marks and to avoid having the front of the engine looking like a painted tree trunk I when over this with the flap wheel.  In full size none of the large components would have been turned.

I spent some time getting the hinge pin to fit in the brackets. Couldn't quite work out the problem - in the end I just made the holes slightly bigger.

Since I intend to paint the smoke box I only temporally fitted the remainder of the components.  I found a bush in the scrap box which I used as a temporary measure to fit the clock.  (I have also through this is the best bit of a steam engine)

A little problem I would never have spotted
ModelWorks have asked me to put a note here regarding a small problem. 

I have just put mine together tonight and I would never have spotted this in a million years.

Foliac
Having taken great care to wear gloves, it's got me.  The Foliac around the chimney has continued to ooze this last week.  I put plenty on as instructed, and with the clamping force of the bolts it is being slowly forced out.  Mike tells me that when he placed his in the oven to cure the paint it was forced out spectacularly.

I shall make sure mine has totally finished erupting before I apply any paint. 

Mike's Burrell
Mike has sent me this super picture of his completed front end.  

Painting
I have decided to put further painting on the back burner. Once kit 6 in complete and the wheel gunk has set it will be time for a major painting session.  By then I hope to have transformed my garage and in the process make it suitable for paint spraying.  I do not want to do any more spraying in my workshop as the paint fog it creates settles on everything.