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LBSCR Terrier No. 72 'Fenchurch' - 2020 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 is to have 'Fenchurch', probably the first Terrier to enter service in 1872, running for its 150th anniversary in 2022.

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 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.

In the reports below, click on photos for enlargements.



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.



 
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