Kit 12 - Boiler, the PrologueModelWorks 4 inch Scale Burrell Agricultural Traction Engine
|
|
Kit 12 will now not be delivered in September. It has been delayed because it has taken ModelWorks longer than expected to sort out the Pressure System Safety Regulation paperwork. Casual readers of this web site may not be aware of the enormity of the tasks faced by Modelworks. Because Modelworks require 80 model steel boilers none of the traditional suppliers are able to cope. ModelWorks only option was to place the order with a commercial industrial boilermaker. Since this is the first time this boilermaker has made model boilers there has inevitably been an increased number of problems. ModelWorks have responded well to the situation by rescheduling other kits so that the overall build time will not be increased. 20/12/04: I have just heard that a snag has thwarted December delivery of the Boilers. 10/1/05: Steve told me that the first boiler has had its tubes fitted and been given an initial Hydraulic test. It had been hoped to use a plate to blank the cylinder fixing holes but this test demonstrated that it will be necessary to individually blank each hole. Unfortunately this is a time consuming job and will limit the rate at which boilers can be tested and delivered to ModelWorks. On the bright side Sun Alliance should scrutinise the official test of the first boiler later this week. The bottom line is that some boilers should be ready by the end of the month but Steve is unsure how many. As it turned out the exact number is zero. Wednesday 19th January: I have just received a standard letter & form from ModelWorks indicating that delivery has now slipped to February and asking if I will want to collect or have the boiler delivered. Steve has sent me some additional info and pictures. I have deleted the cgi that was on this page and below is what they really look like!
While the sea of boilers in these pictures is good news they will only be tested and delivered to ModelWorks in small batches throughout February. After a final machining operation ModelWorks will be using their own transport to deliver each batch. This does mean we will not all be getting our boilers at the same time. We almost got kit 16 (Crank and Flywheel) this month as a substitute for the
boiler but unfortunately it will not be ready in time. I gather that this
will be the February kit. So the kit order will be 1, 2, ... 11, 15, 24, 18, 13,
12, 16, 14, 17, 19, ... 23 - unless it changes! Monday 31 January: Modelworks have taken delivery of the first ten boilers with another ten due next week. See pictures on ModelWorks Website.
This method cannot be used in a "bolt together kit" and so ModelWorks have CNC drilled the cylinder fixing holes. The task now is to drill the stays in just the right place in order to take out any errors that have crept in during boiler fabrication. Steve does not expect the setup to be quick and thinks it could be hours not minutes per boiler. Bearing in mind the criticality of their location we need to continue to be patient. Monday 7 February: Steve has just given me an update on last weeks boiler progress. It is taking 1 1/2 hours to setup each boiler whilst the machining is only taking 4 1/2 minutes. Unfortunately the boilers did not get onto the mill until late last week. So far the first ten have had the stays on the first side machined. The setup for the second side is quick but Modelworks are pondering whether to continue and do the first side of the next batch or the change the mill setup and get the first batch finished. With luck there will be some boilers by the end on the week but predictions in this area have come unstuck before!Monday 21 February: Steve and Dean have just delivered my boiler on their way back from Modelworld Brighton. Even the weather tried to thwart things, there being a snow flurry just before they arrived. Fortunately the boiler is not as heavy as I feared and with some help I was able to get in on my trolley. This will enable me to move it around until it is time for final assembly.
I had put off assembling the hornplates/axle tubes thinking that there was no point - wrong! The instructions call for this assembly, it only being necessary to slacken off some screw to slide it over the boiler (the steering gear should not be fitted). Since the boiler will need to be painted before the hornplates are attached, I will be able to "keep to schedule".
In the next few days I hope to get a good coat of paint on the boiler, especially behind the hornplates and permanently fit the cylinder. Next week we should be getting kit 16 less the crank (Con rod and flywheel). Don't Panic
I
painted the boiler with high heat gloss (the only black gloss I had) using
a 1 1/2 inch paint brush.
Friday: I have just given the boiler its final coat of paint. I had been debating whether to paint the makers plate. It is located on the top of the boiler above the fire box. While it is important that it is readable by the boiler inspector it is a bit ugly.
Saturday: I plan to start fitting the assemblies to the boiler but first I have to finish assembling the hornplates.
Since
this page is getting a bit long the account of assembly continues on this
page. |
Before
the first few boilers can be delivered 8 stays need to be machined, drilled
and tapped for the hornplate fixing. Normal practice would be to
drill the holes in their nominal position and drill the cylinder fixings
in the boiler after assembly. 
The
Burrell has to share my small garage with my car. With snow
falling the "toys" would have to more to their end of the
garage. They don't really mid because their end is centrally
heated.
I had naively expected the hornplate fixings to be roughly central into
the boiler stays, they
are not. I have talked this through with Steve. Apparently
distortion during welding causes an unpredictable "Banana
Effect" and the stays were deliberately made extra large (30mm
dia) in order to provide a large target. Even
if they don't look it, the holes are in the correct position relative to
the cylinder.
The
first task is to paint the boiler since once the hornplates are fitted
this will be impossible. I found there was a lot of gunk on the
boiler and it took a lot of solvent to remove. 
Today I assembled the Hornplates and axle tubes. I have not
previously fitted the axle tubes to the hornplates, fortunately I did
not have any problems. Rather that use the washers supplied to
adjust the length of the bolts, I shortened them in the lathe (There
is no reason this could not have been done with a file - just more
effort).
I
spoke too soon about not having problems assembling the
hornplates. When I came to fit the right hand bearing housing I
found that it fouled the rear spectacle plate. As the picture right
shows I had to unbolt the spectacle plate to fit the housing.
I estimated that 1/16th inch needed to be shaved of the housing.
Before
you could save ModelWorks the housing was on the milling machine and in
no time at all I had refitted it to the hornplate. Fortunately
since the freshly machined edge is against the spectacle plate I
have not spoilt the paint job. 