Wild Rose ~ Quarry Hunslet

[dewintondave]

Merry Christmas all

What tool have you used to recess the front of the wheel? I ground up a special for that job, but sometimes run into problems with chatter.

I'm using the round nose finishing tool that came with my Unimat 3 lathe all those years ago. I'm taking .010" depth cuts with it.

[dewintondave]

Happy New Year

With the latest spell of bad weather I have finished the wheels.

Paint drying in the sun - a few days ago


Front face skimmed.  Tread rough turned on the mandrel


Finish turning the 3 deg. coned tread and flange with a form tool.  The flange is formed


Finished wheels

[Annie]

Very nice indeed Dave

[-steves-]

Awesome, totally awesome, and probably inspiring enough that I may well give mine a go this year sometime Thank you

[dewintondave]

Project scope creep! I'm now favouring the Hunslet Large Quarry Class. It's very similar, the wheelbase is increased from 3' 3" to 4'. Fortunately the wheels are the same diameter. Here's a fine example:- Hugh Napier

[dewintondave]

Whilst waiting for some paint to dry... I've been cutting out the frames from sheet steel. I have a lifetime supply of 1.6 mm

It's hard work with a hacksaw. Filing the edges flat was aided with a long straight edge and sighting through.


Here's the frame blanks cut to length

[dewintondave]

I've been cutting those lovely cut-outs in the frames, lots of sawing and filling. Then lots of drilling for spacers, and heaps of 8 BA tapping in the spacers. I start the tap square in the bench drill. But, first I remove the quill return spring...



Filing, filing


Frames and spacers

[dewintondave]

I've been working on the buffer beams.  The chassis is bolted together.  It was nice to do some turning again, the axle bearings were turned yesterday from gunmetal.



I couldn't resist sliding the wheels on



I've a supply of 8BA screws from my local supplier.

[dewintondave]

The buffer beam height is perfect for the LGB stock...

[dewintondave]

At last a rolling chassis. The coupling rods are finished. I shaped the cranks in blocks of two blanks soldered together, the profile is a bit different between the pairs, so I'll put each pair on their own side of the loco, and not mix them.

Checking the clearances


Rolling chassis


This is how I modify screws. I needed 1/4" AF for the cranks, to keep the rods on, but had no bar stock. I converted four 4 BA screws into 8 BA


Now I need to think about the cylinders...

[Dannypenguin]

Wow this is all looking really good, I'm following this with great interest

[dewintondave]

A month ago I made a gentle start on the smokebox as I wait for some cylinder materials. I'm using steel sheet for smokebox endplates and wrapper



Here's the progress so far. I like using roundhead screws for the rivet look, these were used on the live diesel bodywork

[dewintondave]

Last weekend I started on a flange to mount the boiler barrel to the smokebox.

Disc blank cut out and mounted on mandrel


Outside diameter turned


Centre removed and bored to just pass the boiler barrel OD. Strip cut out and filed flat.


Strip bent to shape around a handy former. Ready for silver brazing


Fully brazed. It took many heatings and adjustments to get the strip placed just right. My first go with cadmium free silver solder


Although a little heat distorted, I was pleased with the concentricity


One week later, boiler barrel fitted to smokebox. 8 BA all the way

[LNR]

Hi Dave!
Nice job, be interested to know what you thought of the Cadmium free silver solder, assuming you have used the cadmium stuff before. Hear many reports of it not flowing as well as the old stuff.
I'm afraid I have enough of the cadmium stuff to see me out, so can't see myself changing, but be interested to hear your opinion.
Grant.

[dewintondave]

Hi Grant, the cadmium free went fine. My old silver solder will soon run out, so I bought a stick of the cadmium free to try. The ring had two spots where it had pooled, I think at the end of the flux line, and me over enthusiastic stick feeding. When the job was finished, I re-fluxed and re-melted them and it flowed nicely without any other aid

[LNR]

Thanks Dave, I reckon your a game man soldering a ring that thin and then machining it to fit. Concentricity doesn't have to be far out when you involve the lathe. Congratulations.
Grant.

[dewintondave]

I made the chimney base from steel. One of the first operations was to mill the smokebox profile on its base. I did this in the lathe, with my old Emco Unimat 3 flycutter.



After milling, the blank was turned in the lathe, working both handles to get the large radius.


The job is secured to the mandrel by Loctite 609 retainer


Lots of heat is required to remove the job from the mandrel, the chimney base is now a lovely blue/black colour

[Keith S]

It certainly is a pleasure to see the work in progress. It looks like a fine job so far. I am particularly impressed with the boiler/smokebox flange.

[dewintondave]

It certainly is a pleasure to see the work in progress. It looks like a fine job so far. I am particularly impressed with the boiler/smokebox flange.

Thank you Keith!

---

Moving to the other side of the smokebox, the smokebox door. This is made from a slice of free cutting steel soft soldered to a mandrel after the rear face was turned.

Rear face details just visible


Profiling the front face


Finished door still on mandrel


Hinge straps cut out of 0.6mm sheet with tin snips


Finished hinges. I used LBSC's "words and music" for the straps and lugs. I had to borrow the roundhead screws from the live diesel



The door is swinging!

[philipy]

Dave,
The big problem with your work is that I ran out of superlatives long ago! As always, I'm in awe.