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LBSCR Terrier No. 72 'Fenchurch'
2020-2022 overhaul


 
Main web page for 'Fenchurch'     -     Earlier overhaul (completed in 2001)     -     Loco Works News
 
'Fenchurch' minus its boiler - Richard Salmon - 18 December 2019 The aim was to have 'Fenchurch', probably the first Terrier to enter service in 1872, running for its 150th anniversary in 2022. However, just as for its 1972 centenary, things didn't quite go to plan, in this case largely down to a small pandemic.

Work started in early December 2019 when 'Fenchurch' entered the Locomotive works, was dismantled to remove the boiler for assessment, and the remainder of the locomotive reassembled for a return to public display in the locomotive shed, as seen in the photo on the left.

The old firebox (an all-steel one made by Luggs of Billingshurst in the late 1970s) has been removed. The outer boiler shell also required a new foundation ring, new lower throatplate, new outer firebox wrapper, 3/4 new backhead, new front tubeplate and barrel extension. With the metal for this delivered, the inner firebox has been assembled by Israel Newton & Sons in Derbyshire, and the outer firebox at Sheffield Park.

To expedite the overhaul, following the loss of workshop time due to COVID-19, the locomotive's frames left the Bluebell on 14 April 2021 for Statfold Engineering in Staffordshire for its bottom-end overhaul, returning in late May 2022, complete with the new cylinder block, cast some years ago, now machined and fitted.

'Fenchurch' was back in steam and cautiously test running during October 2022, a process which continued, with a loaded test run to East Grinstead on 1 December (with the 80-ton Chesham set), and between Sheffield Park and Horsted Keynes in January with the SR-liveried non-corridor set (85 tons) to ensure everything was exactly as it should be, with a formal release into traffic on 10 January 2023, and its subsequent launch into passenger service on 11 February.

In the reports below, click on photos for enlargements.



Finishing touches - Andy Kelly - 27 November 2022
11 December 2022

Since the boiler test, and initial testing and fettling was completed, the finishing touches have been put to the locomotive, as seen in Andy Kelly's photo on the right from 27 November.

This has been followed by a period of running in, to ensure reliable operation once 'Fenchurch' enters service. The photos below, from 1 December, show a loaded test run to East Grinstead and back hauling the 4-coach Metropolitan set (80 Tons tare). Two trips were made, and even with provision of steam heat to the carriages, only half a tank of water was used to reach East Grinstead on each occasion. 'Fenchurch' also happily passed a "re-start from stationary" test on our 1-in-55 climb up to Imberhorne Cutting with that load. It was released into service as of 10 January 2023.

(First photo below: Bluebell Railway, and others thanks to Neil Glaskin and Russell Pearce)


Official Bluebell Railway portrait - James Cummins - 1 December 2022
Fenchurch at East Grinstead - Neil Glaskin - 1 December 2022Fenchurch at East Grinstead - Neil Glaskin - 1 December 2022
Fenchurch approaches Imberhorne Cutting - Russell Pearce - 1 December 2022Fenchurch in Imberhorne Cutting - Russell Pearce - 1 December 2022
Fenchurch approaches Imberhorne Cutting - Russell Pearce - 1 December 2022

October 2022
Assembly of boiler top fittings - Andy Kelly - 6 September 2022 Painting progressing - Andy Kelly - 6 September 2022

Above we see reassembly of the boiler fittings, and painting progressing, as of 6 September (both Andy Kelly). The in-frames boiler steam test was passed on 21 September (see photo below).

No. 72 'Fenchurch' successfully passed its steam test on 21 September 2022

Simon Blaker provides the following record of the boiler work undertaken:

The boiler was inspected when still in the frames during late summer 2019 at the request of the director Chris Hunford.

  • The firebox was seen to be in the later stages of its life with the early signs of fracturing of the firebox corners and welds.
  • We decided at this stage that the 1970s steel firebox would be changed for a new steel firebox to the Israel Newton designed firebox fitted to three other members of this class.
  • The use of this Lloyds approved design was agreed with the boiler inspector and the Boiler removed from the frames late 2019.
  • The boiler tubes were then removed and the boiler rotated onto its back using the workshop cranes.
  • The firebox was then removed to allow inspection of the backhead and throatplates, at this stage we decided to replace a section in the backhead and completely replace the throatplate.
  • The design of the new firebox meant that a new outer firebox wrapper was the easiest and most cost-effective choice.

Other defects and age meant that we finally ended up with:

  • New foundation ring, due to fractures and oversize holes.
  • New fire door ring, due to the old being the wrong size and upsetting the working of the firedoors.
  • New inner firebox, due to thickness, grooving and other defects.
  • New outer firebox wrapper, due to wastage, two old patch repairs and a different stay layout.
  • New throatplate, due to oversize stays, wastage and the early stages of fracturing from the stay holes.
  • New front tubeplate, due to a different tube layout and lamination of the lower section.
  • New 3/4 backhead, due to wastage and a different stay layout for the new firebox.
  • All new boiler stays.
  • A new section of boiler barrel in the form of a 'D' patch, due to localised piting.
  • New injector steam valve standpipes.
  • New whistle valve mounting pad.
  • New boiler tubes.
  • New regulator 'J' pipe.
  • New ashpan.
  • New smoke box with spark arrestor.
  • New smokebox main steam pipe.

In the course of the work we also made up our own crown stay taps, welded and machined in the works.

Test run, at Horsted Keynes - Andy Kelly - 27 October 2022

Test running during October gradually saw the locomotive working up from light movements within the yard to trips up the line, and Andy's photo from 27 October shows 'Fenchurch' up at Horsted Keynes during one such test run.


Porthole view... - Andy Kelly - 31 August 2022
31 August 2022
Reassembly in progress - David Lilley - 29 August 2022

Above we see reassembly in progress, in David Lilley's photo taken on 29th August, and on the right and below, more paint going on, as of 31 August (Andy Kelly).

Painting the top cladding - Andy Kelly - 31 August 2022Painting the smokebox door - Andy Kelly - 31 August 2022

Painting the top cladding - Andy Kelly - 31 August 2022Painting the smokebox door - Andy Kelly - 31 August 2022

Andy Kelly recorded (below) the final placement of LBSCR Stroudley Terrier Fenchurch's boiler in its frames, using the overhead gantry crane in the Loco Works on 15 August. No issues over whether that would fit after the trial run a few weeks back!
Fenchurch's boiler fitted to its frames - Andy Kelly - 15 August 2022Fenchurch's boiler fitted to its frames - Andy Kelly - 15 August 2022

First steam test - Andy Kelly - 9 August 2022
9 August 2022

 

 

 

Andy Kelly's photos record the passing of the out-of-frames steam test, and bacon being fried in the tradition manner for celebratory bacon brioches.

Frying bacon - Andy Kelly - 9 August 2022Bacon Brioche - Andy Kelly - 9 August 2022
During the Terrier 150 event, the incomplete 'Fenchurch' was displayed as best as was possible in the circumstances alongside 'Stepney', as seen in Owen Hayward's photo from 30 July.
Fenchurch and Stepney - Owen Hayward- 30 July 2022

21 July 2022

Fenchurch's boiler has passed its hydraulic test, and boiler fittings are being overhauled and re-attached, as seen in Andy Kelly's photos below. It is hoped that the loco will be assembled ready for display alongside 'Stepney' over the Terrier 150 weekend coming up on 29-31 July.

Boiler fittings on backhead - Andy Kelly - 21 July 2022Boiler fittings on backhead - Andy Kelly - 21 July 2022

Front tube-plate riveting - Andy Kelly - 6 June 2022
6-17 June 2022

 

The frames arrived back from Statfold Engineering on 24 May, but work has concentrated mainly on finishing the boiler. The first three of Andy Kelly's photos, from 6 June, show the fitting of the final tube plate rivets.

Front tube-plate riveting - Andy Kelly - 6 June 2022Front tube-plate riveting - Andy Kelly - 6 June 2022
On 10 June we see below the completion of the firebox, with the finishing off washout plug holes, and the boiler is now being prepared for trial fitting with smokebox and frames.
Inside the firebox - Andy Kelly - 10 June 2022Drilling backhead - Andy Kelly - 10 June 2022
Test fit of Smokebox - Andy Kelly - 17 June 2022

 

 

On 17 June, as seen in more of Andy Kelly's photos, the smokebox and boiler were test fitted in the frames, and pleased to report everything fitted perfectly!

Boiler lifted for test fit - Andy Kelly - 17 June 2022Boiler and smokebox test fitted - Andy Kelly - 17 June 2022

Cab roof, splashers/sandboxes being painted - Richard Salmon - 18 May 2022
19 May 2022

 

At Sheffield Park preparations for re-assembly are progressing with the painting of the cab roof, splashers/sandboxes, and side tanks, as seen here in photos taken on 18 May.

Statfold Engineering's photo shows that the loco is back on its wheels. It is expected back at Sheffield Park shortly.

Side tanks being painted - Richard Salmon - 18 May 2022Frames re-wheeled - Statfold Engineering - May 2022
Andy Kelly's photos below show that our boilersmiths Simon Blaker and Henry Mowforth, assisted by Andy, are making great strides with Fenchurch's boiler. With all the side stays now in place in the firebox, the rivets in the boiler barrel are seen being replaced.
Rivetting boiler - Andy Kelly - 3 May 2022Rivetting boiler - Andy Kelly - 3 May 2022Rivetting boiler - Andy Kelly - 3 May 2022
Heating rivet blank - Andy Kelly - 10 May 2022

 

 

These four photos by Andy Kelly, taken on 10 May, show the process of making the rivets for the front tubeplate.

Making rivets - Andy Kelly - 10 May 2022Making rivets - Andy Kelly - 10 May 2022Making rivets - Andy Kelly - 10 May 2022

Foundation ring and inner firebox, with half of the stays fitted - Andy Kelly - 27 April 2022Outer firebox with new stays - Andy Kelly - 27 April 2022 27 April 2022

 

Staytastic progress. Plenty of tubes and stays to fill in the holes. Two days in and half-way there with stays.

Photos with thanks to Andy Kelly.


New stays - Andy Kelly - 27 April 2022Firebox tubeplate - Andy Kelly - 27 April 2022New tubes - Andy Kelly - 27 April 2022
Foundation ring being rivited - Andy Kelly - 12 April 2022

 

 

A couple of weeks ago, the first rivet goes into the foundation ring as it and the inner firebox are finally fitted.


Foundation ring ready for test fitting to inner firebox - Andy Kelly - 17 March 2022
17 March 2022

 

72's boiler-rolling adventure. Upside down to remove the foundation ring for trial fitting with the inner box and then over to the side ready for NDT (non-destructive testing) inspection on the newly welded washout plug bosses.

Photos with thanks to Andy Kelly.

Note, in the photo below, right, the boiler of Bulleid Pacific No. 34059 'Sir Archibald Sinclair' behind that of 'Fenchurch'.

Boiler on its side - Andy Kelly - 17 March 2022 Boiler on its side - Andy Kelly - 17 March 2022

Riveting the outer wrapper - Andy Kelly - 24 February 2022
24 February 2022

 

Riveting Fenchurch's outer firebox wrapper.

Photos with thanks to Andy Kelly.

Riveting the outer wrapper - Andy Kelly - 24 February 2022 Riveting the outer wrapper - Andy Kelly - 24 February 2022 Riveting the outer wrapper - Andy Kelly - 24 February 2022

February 2022 - Update with thanks to Andy Kelly, Paul Russell and Statfold Engineering Ltd.

Fenchurch's new outer firebox wrapper is test fitted - Andy Kelly - February 2022 Fenchurch's new cylinders in place, and guide bars and valve rods being fitted - Statfold Engineering Ltd - February 2022
The photos show Fenchurch's new outer firebox wrapper being test fitted in the works at Sheffield Park (Andy Kelly) and the new cylinders in place, with guide bars and valve rods being fitted (Statfold Engineering Ltd).

February 2022 Fenchurch News Report (PDF)

Read the full report here (pdf) which contains a full description of recent work, and many photos, both from our own Loco Works and from Statfold Engineering Ltd.


January 2022 - Update with thanks to Statfold Engineering Ltd.

A series of photographs shows progress with the overhaul of Fenchurch's chassis:

Fenchurch's wheels - Statfold Engineering Ltd - January 2022

 

 

The wheels have had full ultra-sonic and MPI inspections and have now been painted in red oxide.

Fenchurch's eccentrics - Statfold Engineering Ltd - January 2022

 

 

The eccentric clusters have been cleaned and assessed. New clamping bolts have been made for these as the old bolts had seen better day.

 

The eccentric rods and weigh shaft (below) have been cleaned and checked over before painting.

Fenchurch's eccentric rods - Statfold Engineering Ltd - January 2022 Fenchurch's weigh shaft - Statfold Engineering Ltd - January 2022

The brake cross bars (below) have been turned to remove the years of wear.

Fenchurch's brake cross bar being turned - Statfold Engineering Ltd - January 2022 Fenchurch'sbrake cross bars - Statfold Engineering Ltd - January 2022

Grinding the valve rods - Statfold Engineering Ltd - January 2022

 

The valve rods have been ground using a tool post grinder on a lathe.

The new replacement cylinders have had the majority of the machining completed. Two sets of cylinders were cast many years ago from a wooden pattern made at Sheffield Park, and the other set are currently being fitted to 'Sutton' at Tunbridge Wells.

The first photo below shows one half of the cylinders set up on the horizontal borer. In the second, both new castings are bolted together and positioned under the radial drill to ream out the joining bolt holes. This is for fitted bolts to ensure the correct alignment and ensure the greatest rigidity for its life in service.

Cylinder on horizontal borer - Statfold Engineering Ltd - January 2022 Fenchurch's cylindera bolted together - Statfold Engineering Ltd - January 2022

Axlebox keeps and repaired horn guide - Statfold Engineering Ltd - January 2022

 

 

One of the horn guide castings was found to have a crack while stripping the chassis. This had been repaired by "Cast Iron Welding services", and new axlebox keeps have also been cast.

Fenchurch's chassis - Statfold Engineering Ltd - January 2022

 

The inside of the chassis has been needle gunned, cleaned and painted in red oxide.

Below: All the horn guide castings have been removed, cleaned, holes reamed and new fitted bolts made. While these have been off, the axle box faces have been machined as well as the horn stay locations and the horn stay studs replaced.

Five of the six new horn stays after machining. It's essential these are a nice snug fit onto the horn guide castings. This helps hold the horn guides and frames square and true, which prevents the axle boxes being trapped within the horn guides and the frames bending/twisting while in service.

Horn guide fitted - Statfold Engineering Ltd - January 2022 New horn stays - Statfold Engineering Ltd - January 2022

June 2021

These photos from Nicholas Smith, show Fenchurch's frames on the traverser outside the workshop at Statfold Barn on 12 June 2021.

Fenchurch's frames on the traverser outside the workshop at Statfold Barn - Nicholas Smith - 12 June 2021 Fenchurch's frames on the traverser outside the workshop at Statfold Barn - Nicholas Smith - 12 June 2021

May 2021

Read the News of May 2021 (pdf) which explains the move of the frames to Statfold Barn, and the plan for the boiler-work.

Click for Acrobat Reader To read the PDF you may need Acrobat Reader. If you don't already have it installed you can download it free of charge from Adobe.



Fenchurch's boiler with the throatplate and inner firebox removed - Tom James - 22 November 2020
2019-2020

See the reports from Bluebell News from 2020 (pdf).

Tom James' photo shows Fenchurch's boiler with the throatplate and inner firebox removed, 22 November 2020.



 
Main web page for 'Fenchurch'     -     Earlier overhaul (completed in 2001)     -     Loco Works News
 
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