Reasons for having a second locomotive
Back in 2006 discussion centred around the idea of having another locomotive on the Corris Railway. A second locomotive would take pressure off the `Tattoo’ when maintenance and repair work became necessary, especially important when it came to the 10 year overhaul of the Tattoo. This might happen as soon as 2015. The boiler would be out for several months while the tubes were removed. Additionally, by having a second locomotive, the work involved in operating the railway could be shared.
What sort of locomotive would we have?
To build another Tattoo might be considered sensible because the design had been accepted by HMRI, but the opportunity to build a locomotive which would closely resemble the original Corris No.3, a Falcon, although fraught with difficulties, was an opportunity not to be missed. To have an appropriately modernised replica of a Falcon would be an advantage to give the railway variety in motive power. Our photo charter friends would love it, the visual display would be more satisfying than two identical twins and it would improve the profile of the railway as a national tourist attraction.
After a poll of the CRS members the decision was taken in the spring of 2007 to build a replica of No 3.
Lack of plans for No 3
The builder of Corris locomotives 1, 2 & 3 delivered in November 1878, was the Hughes’ Locomotive & Tramway Engine Works, Loughborough. It eventually became the Brush Electrical Machines Ltd, Falcon Works, Loughborough and still exists today. The researcher George Toms assured the Society that no plans exist of the locomotive. To obtain drawings the extant locomotive at the Talyllyn Railway must be surveyed (with permission).
Appointment of design & build consultants
Reluctantly our Tattoo Locomotive consultant, Colin Blackwell, had decided for family reasons to take a back seat with regard to the Falcon Project. Fortunately Graham Morris, our boiler inspector, agreed to take responsibility for the project along with a colleague of his, David Potter. In August 2008 they began work on producing drawings by visiting the museum at Corris and then travelling on to Pendre, Tywyn to meet David Scotson (Chief Mechanical Engineer) and John Bate (former Chief Engineer) of the Talyllyn Railway. So began the complicated task of surveying the locomotive and producing drawings. This lasted for nine months and in September 2009 the drawings were complete at a cost of £26,000.
Society members were encouraged to make a gift aided one-off donation or donations by standing order and by November 2008 the fund had reached £22,000. Nineteen members had taken out standing orders. Since then members have been encouraged to sponsor parts of the loco and an updated list of parts is included below including some that can be sponsored retrospectively.
Manufacture of the Locomotive
The decision was taken in 2009 to make the boiler the first item to be built and our two consultants obtained a suitable quote (one of several) from Israel Newton, a 200 year old firm of boiler-makers in Bradford, for £31,250.00 plus VAT. Click here to see this being reported in the Bradford Telegraph and Argus.
Progress to date
The boiler was completed by Israel Newton and was brought to Maespoeth in the late summer of 2012. A good number of other smaller components have also been produced. Once the boiler was received the next move was the cutting of the main frame plates for the locomotive which was done using the water jet method to produce the outside profiles and also all holes needed for bolts and rivets. The frame plates, were taken to the workshops of Alan Keef Ltd for erection.
The driving wheels on the Corris “Falcons” as built in 1878 are unusual for a small narrow gauge tank engine by being larger than the norm at 30” diameter and being solid with spokes cast on (rather reminiscent to the onlooker of the original Tri-ang model railway locomotives of the 1950’s). By way of contrast the wheels on the trailing pony truck which converted the original 0-4-0ST’s to 0-4-2’s with a view to making the original trio of engines ride more steadily were very small with a 10” diameter, but Number 10 will have slightly larger ones of 12” diameter. The wheel centre castings for the driving wheels have been produced and have been drilled ready to accept axles and crank pins at the workshops of Alan Keef Ltd. Steel tyres were produced in South Africa and were fitted to the driving wheels in November 2017.
The axleboxes and bearings have been produced and fitted to the frames and two volunteers with engineering skills had virtually completed the pony truck at the start of February 2018.(components for the trailing pony truck can be sponsored – see below). Quotations for production of the trailing wheels were being obtained at the same time and once these wheels are ready number 10 will become an 0-4-2.. Cylinders were cast in Wolverhampton during 2017. They were due to be machined in late winter 2018 which will take the project closer to the “rolling chassis” stage. A generous individual donation has paid for the casting and machining of the cylinders, plus production of the cylinder covers After this the motion parts will need to be manufactured and fitted in the narrow area between the frames and a further individual donation is helping towards production of the connecting rods.. Subsequent to this the frames area can be united with the boiler once the smokebox has been constructed.
Thus far some £160,000 has been spent on preparatory work and construction of number 10 and the balance of the work has been estimated as being in the region of £100,000. Steam engines, even small ones like number 10, are expensive items to build and the time taken until the engine leaves the Alan Keef workshops and commences work in the Dulas Valley will be determined by the rate of fund raising.
Number 10 will be a recreation of the original Corris Railway tank engines which were constructed in Loughborough in the nineteenth century and one of which continues to work to this day as Talyllyn Railway number 3 “Sir Haydn”. They started life as 0-4-0 Saddle tanks but were converted to an 0-4-2 wheel arrangement to improve riding on the sharp curvature that was a feature of the 2 foot 3 inch gauge line in the Dulas Valley north of Machynlleth. Once completed it will work trains in Dyffryn Dulas alongside the Corris’ first “new build” steam engine number 7 which was completed in 2005 and was overhauled in the Corris’ loco shed at Maespoeth Junction during the winter of 2014-15 with further work carried out at the Statfold Barn Railway at the start of 2017.
Your support would be very welcome if you feel able to click in the donations icon for one of the individual components listed below. Some of these are for parts that have already been manufactured but donors will be able to specifically identify “their” contribution and the money raised will take the project forward. But we do value ALL donations, small or large, so if you would like to help please go back to the main page of the site and click on the appropriate icon there. Thank you in anticipation of the day when the sound of a “Falcon” 0-4-2 saddle tank can be heard again in Dyffryn Dulas.
Donations paid by cheque towards the construction of number 10 can be posted to 38 Underwood Close, Callow Hill, Redditch, B97 5YS. Cheques or postal orders payable to Corris Railway.
SUPPORT THE FALCON LOCOMOTIVE FUND TODAY TO FURTHER SECURE THE FUTURE AND HERITAGE OF THE CORRIS RAILWAY IN THE 21ST CENTURY.
If you would like to make a general donation to the Falcon Locomotive Appeal Fund by credit card or PayPal then please click on this button.
Various parts of the locomotive are already being fabricated and the initial set of parts for which sponsorship is being sought are as follows:
|Item||Cost (each)||Quantity in total|
|(All frame plate parts were supplied with all holes and shaping cut out by the waterjet method)|
|Frame plate L/H||£962.00||1|
|Frame plate R/H||£962.00||1|
|Front buffer beam||£250.00||1|
|Rear buffer beam||£255.00||1|
|Frame stiffening plate||£175.00||1 of 2|
|Frame stiffening plate||£175.00||2 of 2|
|Beam angle||£105.00||1 of 2|
|Beam angle||£105.00||2 of 2|
|Cost of delivery all frame plate parts from Chesterfield to Ross-on-Wye||£190.00||1|
|Cast frame stay parts and assembly|
|Leading frame stay||£100.00||1|
|Intermediate frame stay pattern||£100.00||1|
|Trailing frame stay pattern||£150.00||1|
|Frame stretcher pattern||£75.00||1|
|Leading frame stay casting||£235.00||1|
|Intermediate frame stay casting||£180.00||1|
|Trailing frame stay casting||£230.00||1|
|Frame stretcher casting||£95.00||1|
|Cost of machining leading frame stay||£560.00||1|
|Cost of machining intermediate frame stay||£900.00||1|
|Cost of machining trailing frame stay||£400.00||1|
|Cost of 10 rivets for assembly of frames||£30.00||1 of 4|
|Cost of 10 rivets for assembly of frames||£30.00||2 of 4|
|Cost of 10 rivets for assembly of frames||£30.00||3 of 4|
|Cost of 10 rivets for assembly of frames||£30.00||4 of 4|
|Cost of 20 rivets for assembly of frames||£60.00||1 of 3|
|Cost of 20 rivets for assembly of frames||£60.00||2 of 3|
|Cost of 20 rivets for assembly of frames||£60.00||3 of 3|
|Cost of fully assembling and hot riveting the frames and all associated parts, angles and support brackets||£6,280.00||1|
|Horn blocks and keep plates|
|Cost of machining, drilling and reaming a horn block||£510.00||1 of 4|
|Cost of machining, drilling and reaming a horn block||£510.00||2 of 4|
|Cost of machining, drilling and reaming a horn block||£510.00||3 of 4|
|Cost of machining, drilling and reaming a horn block||£510.00||4 of 4|
|Cost of an axlebox spring plate||£60.00||1 of 4|
|Cost of an axlebox spring plate||£60.00||2 of 4|
|Cost of an axlebox spring plate||£60.00||3 of 4|
|Cost of an axlebox spring plate||£60.00||4 of 4|
|Cost of bolts, washers and binx locking nuts for a horn block and keep plate||£42.00||1 of 4|
|Cost of bolts, washers and binx locking nuts for a horn block and keep plate||£42.00||2 of 4|
|Cost of bolts, washers and binx locking nuts for a horn block and keep plate||£42.00||3 of 4|
|Cost of bolts, washers and binx locking nuts for a horn block and keep plate||£42.00||4 of 4|
|Driving wheel axleboxes and associated parts|
|Cost of machining axlebox casting, axlebox keep, brass bearing and to supply new bronze slipper plates||£2,280.00||1 of 4|
|Cost of machining axlebox casting, axlebox keep, brass bearing and to supply new bronze slipper plates||£2,280.00||2 of 4|
|Cost of machining axlebox casting, axlebox keep, brass bearing and to supply new bronze slipper plates||£2,280.00||3 of 4|
|£2,280.00||4 of 4|
|Firebar castings||£40.00||1 of 11|
|Firebar castings||£40.00||2 of 11|
|Firebar castings||£40.00||3 of 11|
|Firebar castings||£40.00||4 of 11|
|Firebar castings||£40.00||5 of 11|
|Firebar castings||£40.00||6 of 11|
|Firebar castings||£40.00||7 of 11|
|Firebar castings||£40.00||8 of 11|
|Firebar castings||£40.00||9 of 11|
|Firebar castings||£40.00||10 of 11|
|Firebar castings||£40.00||11 of 11|
|Parts for the pony truck which is being made by Corris members|
|Top bridle profiled plates||£95.00||1|
|Bottom bridle profiled plate||£80.00||1|
|Profiled plates and bar for side control brackets||£55.00||1|
|Cast channels||£45.00||1 of 2|
|Cast channels||£45.00||2 of 2|
|Axle block casting||£95.00||1 of 2|
|Axle block casting||£95.00||2 of 2|