Sponsored by William Cook Cast Products Limited

21st July 2008

The tender structure is complete apart from the engine/tender draw bars which Ian Howitt is delivering next Tuesday. The tender plumbing is almost complete (one day’s work is required to connect up air and vacuum gauges). External painting of the tender in grey is complete apart from details such as vacuum swan necks which are being painted as they are fitted.

16th June 2008

The complete mechanical brake assembly has been successfully fitted and subjected to its normal maximum operating pressure. A certain amount of adjustment of the lengths of the long pull rods has been made to ensure that all the brake blocks make contact with their respective wheels at the same time. Considerable progress has been made with the air brake control equipment pipework in the cab area and between the frames.

Ian Matthews has completed the filling and preparation of the tank sides and back and will shortly paint the tank front whilst the brake pipe work is off for hydraulic testing. A screw coupling has been ordered for the tender drawhook. The tender balance weights have been acquired and are in the process of fitting. The injector feed pipes on the tender have been made up and fitted.

27th May 2008

The last of the bolts holding the tender tank to the frame have been fitted along with the steel structure that supports the wooden floor in the cab area. This floor has also been made and fitted. The hand brake screw assembly has been delivered by Ian Howitt and has been tried and fits. Some fitting work had been required on the brake hangers. Otherwise the only remaining brake equipment to be delivered is some pins which are in manufacture.

The tender tank has been grit blasted and Great Northern Steam has been retained to improve the flatness of the sides. Painter Ian Matthews is currently filling, flatting and priming the sides. The reservoir brackets have been secured to the underside of the tank and the reservoirs are being mounted as this is being written. This will permit the air pipework to be completed. The alternator has been refitted. Following individual spring rate checking by the manufacturers, Owen Springs, the tender spring gear has been fitted by A1 Trustees Barry Wilson and Graeme Bunker.

The components for the extended shank rear coupling should be delivered in June which will enable William Cook Cast Products’ Leeds plant to friction weld the stem onto the hook forging – thanks to the intervention of Andrew Cook when the supply problem was discovered. In the mean time the rather worn redundant back draw hook off 60019 Bittern has been purchased which will suffice for the operations on the Great Central Railway.

22nd April 2008

The issue of the strength of the tender drag box has been resolved to the satisfaction of the VAB by partially filling in the obround holes in the bottom face of the drag box and by adding a substantial stiffener plate to the inside of the front face of the drag box where the coupling spring rests. This work was completed on Tuesday 15th April which after a further two days for painting, modifying the mountings for the alternator and alternator regulator and refitting the pipe work, the tank to was lowered and bolted down to the frames on Friday 18th April.

A start has been made on installing tender brake control equipment to the right of the coal doors above the locker. Progress with this should be rapid now the tank is on the frames. Ian Howitt has completed the brake cross stay and has made the final brake pins. The only outstanding items are some hand brake details and the buffers, all of which are in manufacture.

The hand rails have also been fitted to the tank. The reservoir carriers can now be completed and the reservoirs bolted on for the last time. This will enable Tom Snowball to complete the air and brake system plumbing. The tender/engine disconnect points have been fitted with some of the associated pipe work.

24th March 2008

The Trust took delivery of the tender tank from North View Engineering on 6th February during which time it was tried in place and found to fit. It was then lifted again and placed on wood blocks to facilitate completion of work on the plumbing and electrical installation on the frames.

A problem has arisen with the rear drag box. The original drag box design on the A1 tenders was a steel casting. As the pattern work required would have been complex it was decided to use a welded fabrication and although we know one existed, no drawing was found and so the Trust had to commission one. Despite modifications to increase strength they have been found to be insufficient and additional remedial work is now underway scrutinised by DeltaRail. The drag box in its present state is stronger than the original design, but having altered the design (even to a small extent) the Trust is obliged to meet more onerous requirements than those in force in 1948. The overall result of this event is to delay fitting of the tank to the frames as the modifications to the drag box have to be completed before this is done

In the mean time Ian Howitt has delivered the spring hooks and a few smaller items, so the outstanding items are the brake cross stay which is in manufacture and some pins. A set of spring gear has been trial fitted successfully. Ian Howitt has also delivered the tender handrail knobs so as soon as the tank is in position, the handrails can be fitted.

19th January 2008

The tender wheelsets have been subject to ultrasonic and magnetic particle NDT to comply with the group standard requirements and Timken has pressed on the bearings.

The air receivers have been re-fitted and Tom Snowball and Paul Depledge have completed the bulk of the plumbing and electrical conduit respectively The tender springs were delivered on Tuesday 15th January. Most of the spring gear details are now at DLW. Ian Howitt is expected to deliver the spring hooks in mid February. Ian Howitt has made further progress with the brake gear, the bulk of it is now at DLW; he is currently working on the remaining items – mainly the cross stay which is currently in manufacture, some pins and various details of the hand brake mechanism. North View Engineering carried out a hydraulic test of the tank on 1st December which showed a number of small leaks. These have been ground out and re-welded and it was re-tested on 9th January. As soon as the roadway outside the works has been made sound for large road vehicles, the frames and tank will be united. Ian Howitt is also working on the loco/tender draw bar and safety links plus all four buffers. Ian Matthews has continued to paint components and the frames. The axlebox covers were fitted prior to the locomotive steam test as the tender frame had to be run outside to allow the loco out. The tender alternator has been fitted and the belt tensioning apparatus is in course of fitting.

20th December 2007

The tender wheelsets have been subject to ultrasonic and magnetic particle NDT to comply with the group standard requirements and Timken has pressed on the bearings. The tender frame has been delivered to DLW and is now united with the wheelsets. The air receivers have been re-fitted and Tom Snowball and Paul Depledge are piping the frame for air and electricity respectively. Ian Howitt is completing the last of the brake gear, but still has several spring bolts to make, along with the engine/tender draw gear and the buffers.

7th December 2007

North View Engineering of Darlington has completed the tender tank details (coal doors, feed pipe connections, shovel plate etc). A successful water test has been carried out. All springs are on order from Owen Springs of Rotherham. Ian Matthews has painted the axleboxes and covers in grey and axles in finished red gloss. Ian Howitt has completed the brake gear at Crofton and is nearing completion of the spring gear. The main and brake reservoir receivers have been fitted to the tender frames.

The frames were transported to Darlington Locomotive Works and united with the wheelsets on Thursday 6th December. After certain pipe work has been fitted between the frames, the tank will be brought over from North View Engineering and craned onto the frames.

27th November 2007

North View Engineering of Darlington has made good progress with the tender details (coal doors, feed pipe connections, shovel plate etc) and has made significant progress in improving the flatness of tank the sides. They plan to have the work completed by the end of November to enable the water test to be carried out. Ian Howitt is nearing completion of the brake gear and is making progress with the spring gear. The manganese steel liners have just arrived and DLW and this will enable Ian Howitt to complete the spring planks. The secondary rubber springs have now also been delivered from Polytec. Ian Matthews has painted the wheels in grey and the axleboxes and covers will follow shortly. Ian Howitt has almost completed the brake gear at Crofton and under has fitted the main and brake reservoir receivers to the frames. The alternator has also been overhauled and is in the process of being final-fitted to the frames. Elsfield Patterns has delivered the axlebox covers.

Serco Rail has carried out ultrasonic and magnetic particle tests on the tender axles and Timken fitted the bearings to the axles. The frames will shortly be transported to Darlington Locomotive Works and united with the wheelsets. After certain pipe work has been fitted between the frames, the tank will be brought over from North View Engineering and craned onto the frames.

22nd October 2007

North View is progressing with the tender details (coal doors, feed pie connections, shovel plate etc). Ian Howitt is nearing completion of the brake gear and is well on with the spring gear.

The manganese steel liners have been ordered and the secondary rubber springs are due for delivery by Polytec in the near future. Ian Matthews is painting the wheelsets and axleboxes – once this is done the MPI inspection will be arranged prior to contracting Timken to press on the bearings.

16th September 2007

David Elliott attended a meeting with North View on Friday 14th September to review the outstanding details such as coal doors, pipe connections, inspection lid, hand rails etc. The axleboxes have been trial fitted at Crofton and are about to be returned to Darlington. The wheelsets have been to Dowding and Mills in Middlesbrough for balancing – this is now complete and arrangements are in had to paint them prior to fitting bearings. Ian Howitt continues to make progress with the brake gear at Crofton and is fitting pipework for the brake system and electrics (some of which needs to be installed prior to the tank being fitted) and making up the support structure for the air receivers which form part of the locomotive air brake system. The axlebox covers have been ordered from Elsfield Patterns.

13th August 2007

The tender wheels have now been pressed onto the axles and are fitted with tyres. Note the pulley on the rearmost axle for driving the alternator. The wheel sets have been delivered to Dowding and Mills in Middlesborough and the photo shows one set on the balancing rig.

25th May 2007

Great progress with the running gear ! The tender axles have now been delivered to Ian Riley's workshop at Bury.

Since the last update great progress has been made on the tender tank at Northview Engineering. The sheer size of the construction makes it difficult to portray but the photos should give a good impression of this massive piece of metal!

30th March 2007

Whilst at Crofton the tender baseplate was located on the tender frames and all the mounting holes were drilled.
Each hole then has a captive nut above it - these can be seen in the left-hand picture, and more clearly in the enlargement. There are in excess of 100 bolts holding the tank to the frames !!

The work on the baseplate at Crofton is now complete - see note below - and on 26th March it was loaded and transported back to North View Engineering.

7th March 2007

In Sheffield at William Cook Cast Products - Principal Sponsor of the Trust - the tender wheels are ready.

6th March 2007

The tender base plate (with the well tanks completed) has now been moved from North View Engineering to Ian Howitt's works at Crofton so that the mounting points can be determined and fitted.

However !! - the observant ones amongst us will have noted from previous updates that the tender frames were being assembled upside down - this is by far the easiest way to do it.

So, before the base plate could be fitted the frames had to be turned over.

16th February 2007

Some serious pieces of metal are taking shape for the tender! At North View Engineering work proceeds on the tank.

First the the tender base plate was made, then the tender well tank, and then they came together!

Meanwhile, at Ian Howitt's workshop in Crofton work continues apace on the tender frames. Recent trial fittings have been the alternator and the air brake cylinders.

15th January 2007

Work continues on the tender frames at Ian Howitt's workshop in Crofton near Wakefield. Currently the activity is focussed on making and fitting the brake rigging.

In Darlington North View Engineering are waiting for delivery of the materials for the tank. When these arrive construction of the tank will commence.

The castings for the wheels and axleboxes have been done by sponsor William Cook Cast Products. Axles are on order as are the tyres and bearings. When all components have been delivered then Riley & Sons in Bury will assemble the wheelsets.

19th August 2006

The tender frame is now virtually complete, requiring fitting of footsteps and two pieces of angle. A dimensional survey has indicated that the frame is correct within tolerance in length, distance between frame plates and squareness. The horn faces still require truing up, but it has been agreed that this will be done when the axleboxes are finished, in case there are any problems with the axleboxes that may require a concession on the final dimensions of the hornblocks.

The wheel and axlebox design has been subjected to preliminary scrutiny by the VAB and approved for patterns and casting. A reply on the detail design of the axleboxes is awaited from Timken but as this is most unlikely to affect the pattern and casting process, drawings have been forwarded to William Cook for patterns and castings.

Work on finalising the tank drawings is nearing completion and it is expected that they will be sent out for quotation during August 06.

A revised layout has been schemed for the brake actuating gear to facilitate conversion to air brakes from the original steam operation. Brake cylinders have been ordered from Metcalfe Railway Products and are identical to those on the locomotive. The redesigned brake cross shaft and hand brake arrangement is being detailed and stressed by a contract designer/draftsman. The final installation of the cylinders looks to be fairly straight forward as they will mount on plates welded directly to the front drag box, eliminating the requirement for the complicated frame stay that supported the original steam cylinder design.

Following VAB approval, the brake levers which support the brake blocks are being fabricated from mild steel plate rather than forged from solid. The profiles have been delivered and are being bent where necessary prior to having bosses welded on. The brake shaft bearings have also been fabricated. I D Howitt Limited are progressing the procurement and fitting of brake levers and rods and suspension parts.

An iron casting has been made for the handbrake screw support.

Spring hooks and other forged components for the suspension and brake parts have been ordered from Heskeths of Bury.

A coach alternator including control gear has been recovered from a scrap vehicle and is being offered up for making a suitable mounting on the rear drag box . This will be the primary source of 24V DC when the locomotive is moving being much more efficient than the steam turbo generator on the locomotive, which will still be available for extended stops or if the alternator fails.

July 2006

The tender for Tornado is the subject of a major sponsorship deal with The A1 Steam Locomotive Trust’s principal sponsor, William Cook Cast Products Limited. The actual construction of the tender will be done by I D Howitt Ltd

Construction is well under way with the frames having been profiled from 25mm steel plate, and the edges machined where required by Multitech Ltd at Featherstone

William Cook Cast Products cast the hornblocks, spring hook bracket and spring safety brackets in steel at their Burton foundry and then machined them at their Tow Law facility.

The hornblocks have been sent to North View Engineering Ltd at Darlington to have the manganese steel wear plates welded on. North View are have also fabricated the front and back drag boxes.

It is intended that the tender tank will have the same outline as the original design, however the new tank will be of all welded construction and have the internal proportions altered to carry more water and less coal.

Completion of the tender structure is linked to progress with the locomotive and is scheduled for 6 months before the locomotive is completed, to allow for fitting brake and electrical equipment.

Here are some illustrations of the progress of the frames to date