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BOILER BUILDING + Other Projects by STEAMHEATON
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   Author  Topic: BOILER BUILDING + Other Projects by STEAMHEATON  (Read 31030 times)
kapullen
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Re: BOILER BUILDING + Other Projects by STEAMHEATON
 
« Reply #1080 on: Jun 30th, 2014, 8:49am »
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Here is the left cylinder as received.
 

 
This engine came to be as a casting set from a vendor at train mountain.
It was in the works for several years and survived a bankrupsy
at the first shop that machined the castings.
 
It was finished machined, and assembled by another shop west of here (east coast).
The workmanshop on the running gearlooks nice and crisp.
 
Whom ever fabricated this engine could jump in and enlighten us  
a bit more about it's history.
 
 
I disconnected an oil line fitting in the smokebox and rotated the pump  
and got a bit of water then nothing from the line.
 

 
The pump had oil in it.
 
The liners both sides, and pistons were brass, or bronze
with nice gall marks in them.
 
The rings were "plastic" as received, with a wave spring underneath
to load them.
 
 
 


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kapullen
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« Reply #1081 on: Jul 1st, 2014, 1:34pm »
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When I received it the mechanism was free, and guides appeared to be setup right but maybe a tad tight.
 
 
Mike at the club had  taken this engine apart and found that over sized (2.5 or larger) automotive rings
were used. These had been gaped to go in the 2.375 diameter cylinder. He had to pry them out of the grooves.
 
You can reduce a rings diameter a a couple thou, but not 1/8 of an inch.
That extreme reduction will give excess pressure at the gaps and a couple other areas.
 
The gall marks appear randomly spaced around the cylinder.
 
 

 
Mike installed the plastic ones and advised the owner to run it.
It probably would have been fine for a couple years anyway.
 
The owner wanted the liners removed, and replaced with Cast Iron.
 
I tried to pull the brass liners with a 4140 all thread rod
and nuts. That was not successful.
 
Then I looked for a porta power rental with an industrial
twin ram jack setup.
 
No one in this town has one. The twin setup allows you to  
put a draw bolt thru the center hole of the jack, and pull liners, bearings
or whatever with minimum head room.
 
The twin ram setup costs $650+ so I opted to make a twin ram.
 

 
 
I built a twin cylinder jack from a piece of cast iron bar and
pieces of crs bar as pistons, and cross bar.
 
This is to work with my brand new Harbor Freight
Hydraulic Jack.
 
This engine like most, was designed to allow room behind the front beam  
to get a line boring rig in for overhauling the cylinders.
 
First day I looked at the engine I crawled to the fromt of the trailer
to check this space out. I didn't want to get involved in removing the front  
end of an engine to work on the cylinders.
 
 
This, the twin jack, was un successful too. I didn't want to force the  
issue and break the block.
 
I always have in the back of my mind how brittle
cast iron is and handle it with care.
 
I worked cast iron castings for many years and have seen a couple  
expensive castings broken.  
 
I have since found the liners to be loctited in place.
They may have even been allowed to float in place in the goo.
 
I built a liner splitter from a Harbor Freight arbor press (2 ton). The rack and pinion
were mounted in a bushing to act as a hand operated broaching tool.
A few new teeth had to be added to the jack ram to get enough stroke
with the cutting tool. The shaper made quick work of the new teeth.
 
 
 
 
The cutting tool is held in a square hole bushing loctited in the jacks ram.  
 
The square hole bushing has a thread in one end allowing advancing of the tool for each pass.
 
Back in the day, these bushings were used to fabricate all manner of boring bars, and cutters
to match the application.
 
 
 

 
 
Here is the splitter in the bore.
 
Once the liners were slotted thru, I put some pressure on the left liner with the  
jack.   It did not immediately break loose. After about five minutes a popping sound occured.
Inspection revealed the left hand liner had moved about 3/8 inch.
 
 


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kapullen
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« Reply #1082 on: Jul 1st, 2014, 1:51pm »
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Here is the splitter at work.
 
www.youtube.com/watch?v=H48xz4QJB9E


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Henry
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Re: BOILER BUILDING + Other Projects by STEAMHEATON
 
« Reply #1083 on: Jul 1st, 2014, 2:02pm »
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That's quite a job. Very interesting.
 
Henry


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Dan Watson
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Re: BOILER BUILDING + Other Projects by STEAMHEATON
 
« Reply #1084 on: Jul 2nd, 2014, 10:59am »
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Kap,
Very interesting method for removing the liner.  
Question: did you consider heating the casting to "kill" the loctite bond? This might not have been possible without removing the cylinders from the loco.


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kapullen
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« Reply #1085 on: Jul 3rd, 2014, 12:13pm »
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Dan,  
Yes, I thought about heat, and also about stuffing dry ice in the liner to shrink
it.  
Didn't want to mess the paint up any more than necessary with heat.
Glad I went this way because the block has tapered bores and I pulled the liners out the small end!
kap


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« Reply #1086 on: Jul 3rd, 2014, 12:21pm »
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Once the liners were slotted thru, I put some pressure on the left liner with the  
jack. It did not immediately break loose. After about five minutes a popping sound occured.
Inspection revealed the left hand liner had moved about 3/8 inch.
 
 

 
 
It was then a matter of jacking the liner out using the grade 8  1/2" thread, hardened nuts
and cast iron jacking spacers made for the job.
 
 
Upon measureing the bores, I found the bores in the casting were tapered.
The left side tapered .006" and the right tapered .011".
 
I had pulled them out the small end!
 
They were large in the rear end of the block. Evidently tool wear caused the  
tapered bores.
 
The new liners had to be individualy made to match the different tapered bores.
These were easily programmed and turned on my Prototrak CNC lathe.
 
The liners were installed using the trusty grade 8 all thread rod, and nuts to pull them in place.  
 
I allowed about .001-.002 press fit in the bores. New 2.375 cast iron rings  
came from OTTO GAS ENGINE WORKS. They are located in Elkton Maryland and stock many
sizes and styles of rings from model sizes to 80 plus inches.
 
    www.ringspacers.com
 
The home made rings were not to spec.
 

 
The rabbit on the right head in the bore was loose. This would cause problems with  
future assembly, and crosshead guide bar resetting.
I used my put-on tool to displace some metal on the rabbit diameter and remachined it for a neat fit.
 
 
Fitting the guides.
 
I run the piston all the way into the bore, and shim the cross head end guide bar for.002 clearance.
Set the other end, crosshead all the way out, splitting the difference in any free motion of the crosshead
and setting the same clearance. Re check from end to end until ok and tighten if prefered.
 
A new Little Engines oil pump is mounted on the far side from the non working pump.
 
In the garage with a blanket and 100 watt light bulb to keep her warm.
 
 
 

 
 
We arrived at the track Sunday and started a fire with some wood blocks. After a while we noticed the  
grate support bars weren't in the hanger rings. Had to lift the grate and guide the pin  
and tap the other side to go in the hole.
 
By that time the pressure was up and the water appeared low. The injector showed no sign of life and the only pump  
is a twin axle pump under the engine.  We pulled the fire with the shovel with 100# pressure.  
The injector sputtered to life.
 
The water glass returned to 3/4 full after blowing the glass down.
 
We had killed the fire for nothing.
 
The drain cocks are stopped up. We eased the engine back and forth with a little steam but mostly pushing to warm the cylinders.
 
A couple steam pipes are split to the whistle and brakes from the two cold winters.
 
 
Finially Dave, the owner got on and ran most of the afternoon without a hitch.
The twin boiler pump and injector were then working.
 
 
Being that it was private club run day, he went without brakes. There is always reverse anyway.
We have a couple issues to work on, and a new set of stainless grates to fabricate.  
 
Kap
 
 


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Dan Watson
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Re: BOILER BUILDING + Other Projects by STEAMHEATON
 
« Reply #1087 on: Jul 4th, 2014, 11:22am »
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Wow, that turned out to be quite a job! Sounds like it went the way a lot of my projects go: everything goes smoothly until you start!

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kapullen
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« Reply #1088 on: Jul 7th, 2014, 3:17pm »
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Dan,
 
Funny,
 
I thought I'd just have to pull them out with a piece of acme threaded rod, and a bit of dry ice,  make the new iron one's, and pull them  in!
 
It took a while to think up that Harbor Fright broach rig.
 
I got lots of advise from many different people like Van Norman boring heads,
and line boring rigs.  That broach tool seemed the best way to go.
 
Now I have an extra arbor press to junk up the shop.
 
Kap


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SteamHeaton
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Re: BOILER BUILDING + Other Projects by STEAMHEATON
 
« Reply #1089 on: Jul 28th, 2014, 12:04pm »
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Kap
 Looks like you had to deal with the same problems I experienced.  I enjoyed the pictures and explanation of your fix.  Im glad I did not have to change out the liners. Not yet anyway.  Ray III  


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SteamHeaton
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Re: BOILER BUILDING + Other Projects by STEAMHEATON
 
« Reply #1090 on: Jul 28th, 2014, 12:13pm »
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BandM_Jim
 I definitely plan on building the hoppers. Not exactly sure when , hopefully in the next year. I will post pics of my progress as I go. So many projects and never enough time. I still need to finish the mike, and I plan on rebuilding the Raritan this winter, with hopes of taking it to train mountain next year. Im glad you enjoyed the boiler build project.  Ray III  on Jun 3rd, 2014, 11:28am, BandM_Jim wrote:       (Click here for original message)
Hi Ray -  
 
I've been watching your boiler build for years.  I liked the start of the hopper building thread.  Any chance you will continue with that thread ?
 
Thanks for sharing your boiler building experiences.
 
    - Jimi -
    Harvard, MA



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SteamHeaton
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Re: BOILER BUILDING + Other Projects by STEAMHEATON
  IMG_20140816_214323_144_816x460.jpg - 48931 Bytes
« Reply #1091 on: Aug 16th, 2014, 11:44pm »
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I have finally started the cab.  Mocking up with poster board. Then use those as templates to be cut out in steel. Ray III

http://Forums.Railfan.net/Images/LiveSteam/IMG_20140816_214323_144_816x460.jpg
Click Image to Resize

« Last Edit: Aug 16th, 2014, 11:47pm by SteamHeaton » Logged
Pennsy4483
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Re: BOILER BUILDING + Other Projects by STEAMHEATON
 
« Reply #1092 on: Aug 18th, 2014, 9:27am »
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Looking good Ray!  Keep up the good work and keep the photos coming.
 
Don


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BobbyT
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Re: BOILER BUILDING + Other Projects by STEAMHEATON
 
« Reply #1093 on: Aug 30th, 2014, 11:32pm »
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That is great Ray! I can't wait to see it finished!

« Last Edit: Aug 30th, 2014, 11:33pm by BobbyT » Logged
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