Rheilffordd Corris Railway

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Author: Andy Cooper

Photographs taken between 23rd April and 9th September 2023

30th November 202330th November 2023 Andy Cooper 0 Comment Photographs

One of a batch of cladding sections for the inside of the carriage being glued up

This area will be the small guards compartment in Carriage 24. The fabrications for this have been slightly modified

While some of the parts are prepared at home most of the fitting onto the carriage has recently been done by Robin. Clerestory window surrounds and one of the guards partition panels being quite recent

Panels in the vestibule are also progressing

One of the centre end roof panels with the curved fold being formed

Centre roof panels fitted to the carriage

Aluminium roof panels for Carriage 24

Each end of the side roof is capped off with a small aluminium fabrication. This is the start of forming the shape

With the step partly formed

The finished items before painting

With the outside primed and the inside varnished the glass was fitted to the drop window for the north end

After planing the edges hardwood boards have been glued together to form the upper inside end panels

Here curved Meranti strips are being cut out which are then made into U section claddings for the curved roof supports

Ian on the Router having a Cool Dude moment

Photographs taken on 31st August 2023

2nd September 20231st September 2023 Andy Cooper 0 Comment Photographs

The Falcon loco at the water tower

Thursday, 31.8.2023. An early start to make preparations for some initial driver training and train movements - light engine only.

Not a usual view of the locomotives in the engine shed as work continues. Final items can now be added, ready for tomorrow.

The Falcon loco then makes it's first exit from the engine shed into Maespoeth Yard.

Time for visual checks and of course more photographs.

Having reversed out of the yard the loco then ventures onto the main line to get to the North Platform ...

... crossing the designated pedestrian walkway ...

... before returning.

The available crew have trial runs to experience the new loco in steam.

The loco then heads into the coaling area to take on coal ...

... and then is positioned at the water tower to take on the water it needs.

It is a bit of a damp day but that does not stop proceedings ...

... as Patrick ...

... and David take their spell in the cab. With the essential and much needed mug of coffee you will notice.

Dave then brings the loco back into the engine shed for the night.

Photographs taken on 26th June 2023

28th June 202328th June 2023 Andy Cooper 0 Comment Photographs

Monday, 26.6.23. Loco No. 10 has now been partially stripped with boiler insulation and cladding being the next jobs

These are the rolled angles that will be attached to the boiler to create a space for the insulation and a fixing for the cladding sheets and bands

A good view of the lovely pipework for the air brake system

Just arrived, this valve is the final component needed for the air brake system it controls the steam feed to the pump

Recently made cylinder covers have been fitted

The blow down valve has been fitted and a hinged cover arrangement fabricated to protect it

Photographs taken between 7th & 10th April 2023

13th April 202313th April 2023 Andy Cooper 0 Comment Photographs

Friday, 7,4,2023. Progress has been made on carriage 24 thanks to the recent efforts of Robin, Zach and Theo.

Setting up to fit the boards to the centre of the roof.

With the boards fitted.

Next a triangular section of timber was screwed and glued to the edges of the roof which will support the aluminium skin.

Fixings for the handrails made up some while ago by Adrian were drilled and tapped.

Also the vestibule handrail and half round beading.

After hefty sanding to clean them up the seat slats for the north compartment fixed seat were given a coat of varnish.

And screwed to the frame.

Photographs taken between 23rd & 28th October 2022

1st November 202231st October 2022 Andy Cooper 1 Comment Photographs

Carriage 24 photographs by Andy Cooper and the Waggon Shelter photographs by John Davey.

Saturday, 22.10.2022. It is AGM Saturday at Maespoeth with a multi talented gang working on carriage 24. Here Theo is seen fitting window beading to the south end

Sunday, 23.10.2022. On the Sunday Graham, Zach and Theo had been joined by Robin. Excellent progress was made mainly in the north compartment.

After fitting cant rail capping sections and sills the vertical U sections were fitted. All needs to be snug to fix the glass tightly

Graham, Theo and Zach having made good progress before long trips home

The north compartment with more of the steel frame hidden from view and seven more windows fitted

Carriage 24 now with more glass fitted and the recent addition of half round beading thanks to Robin's efforts

Sunday, 23.10.2022. The main October Workweek task was to slate the waggon shelter roof.

Both Sides.

Ian reviews the instructions before starting ...

... and then starts on the first row

John D has been cutting the slates needed for Ian to make good progress.

Tony H comes to check how things are going ...

Monday, 24.10.2022. ... before starting on the other side ...

... and he too is soon making good progress

He is getting towards the ridge

Ian joins him and even faster progress is made.

The liquid sunshine holds things up.

Tuesday, 25.10.2022. Besides cutting slates John D is called upon to scramble to the top to fix the top row of slates beneath the ridge ...

... and soon the ridge slates are in place ...

... and John has been cutting and fixing reeves to finish of the ends.

A very satisfied team takes a well earned break before fixing the guttering.

Wednesday, 26.10.2022. By the Wednesday evening the job is complete.

Friday, 28.10.2022. With the first of the autumn leaves already in the gutter.

Photographs taken between 14th July & 17th August 2022

18th August 202218th August 2022 Andy Cooper 0 Comment Photographs

Thursday, 14.7.22. The base ring for the tank filler being rolled to shape

The reinforcing D shaped part was rolled likewise

Graham made jigs for pilot drilling the dummy rivet holes

Which were then opened out to size with a magnetic base drill

The tank with most of the rivets welded in, the cast iron pocket in place and the tank filler fabricated

Lowering the inner shell into place

After welding the inner shell holes were cut through outer and inner shells. There is a central tube to clear the steam dome. The tube was made from two rolled plates which were welded together after trimming.

Almost complete just the bottom weld on the tube to finish

With the fabrication complete the tank was etch primed and primed

The inside of the tank was painted with underwater primer and topcoat

Graham provided digital drawings so that Tennant Rubber Ltd in Nottingham could supply the seals needed

Wednesday, 17.8.22. Andy and Ian arrive at Alan Keef Limited with the saddle tank delivery from the East Midlands

The important cargo gets delivered into the workshops by fork lift truck

Andy discusses the fabrication of the saddle tank with a member of Keef's staff

The completed tank was delivered to Alan Keef Ltd to within feet of it's final destination and where Ian and Andy were able to view progress on the loco

Some interesting fabrication has taken place

Andy takes the opportunity for a close inspection of the smokebox and the door fittings

The plumbing inside the smokebox has all been completed

"I reckon it goes here!"

The locomotive now looks the part with the smokebox door and darts in place - almost "ready to go"

Photographs taken between 4th & 26th July 2022

8th August 20228th August 2022 Andy Cooper 0 Comment Photographs

Monday, 4.7.22. The regulator handle, operating shaft running forward, mounting bracket and quadrant fitted to the boiler. All photographs courtesy of Alan Keef Limited.

Wednesday, 6.7.22. In order to drill and countersink the smokebox wrapper a special jig was used to account for the awkward shape and the fact that magnetic base drills don’t stick to stainless steel.

Sunday, 10.7.22. Using the smokebox as a guide the boiler was drilled for the fixing screws.

Tuesday, 12.7.22. Looking a step closer, Corris Railway loco No. 10 with the smokebox wrapper in place.

Next the boiler was removed from the frames for the necessary hydraulic boiler test ...

... and the opportunity was taken to drill the final hard to access smokebox fixing holes.

Wednesday, 20.7.22. The mounting flange for the main steam valve has been machined and fitted. The new valve shown will be getting a more appropriate handwheel in due course.

Sunday, 24.7.22. The hydraulic test was passed without a problem.

The ashpan has been fabricated complete with sliding bottom plate.

Tuesday, 26.7.22. This picture shows the tight clearance between the brake gear, trailing truck frame and the sliding bottom of the ashpan.

The side control springs have been fitted to the trailing truck.

The boiler has now been refitted to the frames.

Photographs taken between 21st June & 6th July 2022

7th July 20227th July 2022 Andy Cooper 0 Comment Photographs

Tuesday, 21.6.22. Nicely swept steam pipes from the regulator housing to the cylinders have been made up for the Falcon loco at Alan Keef Ltd.

Pipework for the exhausted steam from the cylinders has also been fabricated.

A good view of what will be inside the smokebox.

The blastpipe will be next ...

... expertly fitted and spotless inside.

Wednesday, 22.6.22. Parts for the Falcon loco have been formed by Barnshaw Plate and Section Rollers in Bilston. Visible on the trailer are the cab roof along with the inner and outer shells for the saddle tank.

Tuesday, 28.6.22. Checking the fit of the inner shell.

The outer shell is tacked to the end plate.

Friday, 1.7.22. The tank bottom plates have large rectangular holes for access as on loco No.7. Captive nuts were welded on as fixings for the cover plates.

The shells were slightly overlong to allow for rolling but only about 10mm needed to be trimmed off.

Monday, 4.7.22. One of the bottom plates tacked in place.

Tuesday, 5.7.22. Both bottom plates welded on and ground back.

Photographs taken between 14th & 20th February 2022

22nd February 202222nd February 2022 Andy Cooper 0 Comment Photographs

Monday, 14.2.2022. The new Salter spring balances for Falcon Locomotive No. 10 have been collected.

They were made by Graham Redfearn (pictured) who usually repairs and restores clocks

For context these are the original Salters on No.3 attached to the arms linking to the safety valves

Wednesday, 16.2.2022. Graham French has brass castings that will form the edge moulding on the cab sides produced from his drawings and 3D printed patterns. (GF)

Saturday, 19.2.2022. Ian has been busy machining safety valve seats for the loco.

Which are a press fit in the steam dome.

Sunday, 20.2.2022. Followed by the actual valves.

The machined valves and seats.

Photographs taken between 5th & 19th August 2021

20th August 202120th August 2021 Andy Cooper 1 Comment Photographs

Thursday, 5.8.2021. The trailing truck is prepared to meet up with the Falcon Locomotive chassis. All photographs courtesy of Alan Keef.

We have a 0-4-2 !

The brake stand awaits it's turn too.

Tuesday, 10.8.2021. What we have all been waiting for! The boiler meets the chassis for the first time.

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