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Kit 14/15 - Boiler

 
The Foden Boiler manfactured by John Rex Model Engineers

Monday 18 February 2008:  My boiler arrived by special delivery early this morning. I am not sure what kit number this is but until I know differently I am counting the boiler as Kits 14/15.  Two numbers are needed as the boiler counts as two kits. Paul kindly placed the boiler on my trolley.  I have recently devised a cunning plan, namely to build up the engine around the boiler.  The primary reason for this is lack of space since without the Foden chassis and load platform it will be much easier to accommodate it and my Burrell in my small garage.  A secondary advantage it that I will not need to lift the boiler into the chassis as I shall build the chassis up around the boiler.

CAD view of engine assembly

I am not sure how far I will be able to proceed with the assembly but I am fairly confident I can get as far as shown in the illustration.  I expect a fair degree of fettling will be required to get the engine running sweetly on air and I will have the advantage of excellent access.  It is just possible that I may be able to fit the 2nd shaft and geering but I may come unstuck as the 2nd shaft support bracket is fixed indirectly to the chassis support bracket.

No instructions were supplied with the boiler.  This is not a particular problem as until the hornplates arrive there is little to do other than paint the boiler.  Unlike the Burrell the boiler has no cleading so I had better do I neat job.  When I last contacted Steve he was hopeful that the hornplates would go out at the end of the month.

The cleaned boiler ready for painting

As well as looking nice the paint has to protect the outside of the boiler from rusting and it is therefore vital to prepare the surface throughly.  After giving the boiler a going over with a wire brush in my power drill I washed the boiler with water containing a little washing up liquid.  Judging by the water this removed a lot of rust and dirt but the surface still looked dirty.  I decided to step up a gear a fitted a brand new flat wheel to the power drill and used this to get as much of the surface steel colour as possible.  As I was having difficulty reaching the underside I upended the boiler by roiling it onto wooden block.  I have no intention of ever lifting it!  After another wash I tackled the hard to reach places with a combination of emery paper and wire brush  followed by another wash.

After the first coat of paint

The boiler now looked clean but a  wipe over with a cloth soaked in thinners demonstrated that it was far from clean.  Finally after many wipe overs with thinner laden cloths the boiler was clean and ready for painting.

Consulting my instructions for the Burrell Steve does not mandate high temperature paint.  I am not sure why this is not necessary.  Perhaps its because black paint can't be darken by heat!  Being a rebel I used Halfords high heat on the Burrell and I used this again on the Foden.  I applied the first coat with a 1" brush and according to the can I need to wait 72 hours for the second coat for which I plan to have the boiler horizontal.

The saddle is a tight fit on the boiler

I have just trial fitted the saddle onto boiler and found that it was a very tight fit.  With studs in one side of the boiler the holes on the other side do not line up by about "1/2 a hole".   In places I can see daylight between the boiler and the saddle while in others it is scraping the paint.  I suspect that boiler barrel is no longer perfectly round as a result of distortions during the welding process.  I shall remove the paint and have another go but I suspect I will have to file parts of the saddle to get it to match the profile of the boiler.

Filing the saddle to fit the boiler

I have just spent the afternoon improving the fit of the saddle.  Looking at it as a clock both ears of the saddle were binding at 9 and 3 o'clock.  I was  surprised that the only other place at which the boiler touched the saddle was at 8 o'clock.  There was daylight from 8 o'clock all the way back to nearly 3 o'clock.  Removing the paint made little difference so I attacked the saddle with a half round file at the 8 o'clock position.  On refitting the saddle I found I had reduced the amount of daylight at the 6 o'clock position but I still had a way to go.  I used a feeler gauge to confirm where the saddle was touching and continued filling and retesting for the rest of the afternoon.  I now have the saddle touching at 6 o'clock (as well as 9 8 & 3).  As yet the holes don't line up but I hope that if I persevere I will succeed .  I don't want to remove too much metal in one go as I want the boiler to rest on the saddle particularly around 6 o'clock where the weight of the front of the engine is transmitted to the wheels.

Wednesday:  After much filing I have finally managed to get the the fixing holes in the saddle to line up with those in the boiler.  Judging by the pile of iron filling around my workbench I have removed quite a lot of metal.  I have concluded that the tight spots correspond with ridges in the boiler barrel perhaps left by the dies used in the rolling mill.

Thursday 13 March: There is a kit 15 but unfortunately I was overlooked and have only just received it.  Kit 15 contains the manhole cover, fusible plug and cylinder gasket.

The contents of kit 15, the boiler basic accessories

I am currently in the middle of preparing kit 16 and will put this to one side.  I will probably fit the cylinder as soon as I can but those constructors who need to lift theboiler into the chassis should delay until all boiler lifting is over and done with.