Model Engine Maker

Engines => Restoration of Model Engines => Topic started by: doubletop on July 25, 2012, 11:20:21 AM

Title: Another Simplex Refurbishment
Post by: doubletop on July 25, 2012, 11:20:21 AM
Both Stu and me purchased a Simplex loco for refurbishment around the same time last year. Both of us have had other stuff on the go before we made a start on our separate projects. I've been working on mine on and off and apart from a few pics here and there I haven't started a thread. There's not much to be seen making new bushes and pins etc. Anyway now Bogs has started this new forum and there's a topic on restoration I'll start a thread here.

(http://i.imgur.com/A0Bi6eG.jpg)

This loco was built in 1994 as a joint effort by two well known NZ loco constructors and,about 4 years later,  purchased by one of the then presidents of a local club. It seemed to earn its keep and looks like it had worked hard. It came with good documentation including photos taken in 2002 of defects that needed dealing with. Those same defects still needed work so I'm assuming not much had happened in the intervening 10 years.

First job was strip it down

(http://i.imgur.com/VW0ghpU.jpg)

(http://i.imgur.com/ZErAmh0.jpg)

(http://i.imgur.com/5XbHXsg.jpg)

(http://i.imgur.com/xFtwyMi.jpg)

As you can see it was a bit grubby and plenty needed doing

Pete
Title: Re: Another Simplex Refurbishment
Post by: doubletop on August 24, 2012, 10:26:00 AM
OK I'm going to fast forward this a bit. I cleaned up everything and re-painted the frames etc

(http://i.imgur.com/8kZBb51.jpg)

(http://i.imgur.com/bCgqlO9.jpg)

(http://i.imgur.com/TacXPM9.jpg)


Things then moved on further and the motion re-furbished, port faces skimmed and polished, new pistons, rods and CI rings, new cross heads, every bush replaced, all pin holes reamed up to the next metric size and all new pins. everything that needed it case hardened.  I didn't see much point in showing photos of all that and cleaning stuff. so here were are and I got all the running gear back together and gave it a blast of air.

http://www.youtube.com/watch?v=NoilRuuiIYQ


Things weren't quite right and I called one of the club members who was going through a similar process on a 7.25" Phantom (NZ origins) I then decided to purchase Don Ashtons valve gear book. I had many evenings trying to make sense of it. Then lights went on and the realisation that the expansion link needed work to take out the wear in then die block. Through another forum I even ended up in a dialogue with the man himself. Now the valve gear is way better than it was in the video above. A bit of blow by on the piston rings but I'm told that should sort itself.

Pete


Title: Re: Another Simplex Refurbishment
Post by: ozzie46 on August 24, 2012, 12:00:45 PM


    Great job Pete. She sounds nice.

     Ron
Title: Re: Another Simplex Refurbishment
Post by: sbwhart on August 24, 2012, 01:43:47 PM
Down the line a bit than my re-build Pete, Great job seeing that will give me a kick to get more done, looking forward to seeing it in steam.

Stew
Title: Re: Another Simplex Refurbishment
Post by: steamer on August 24, 2012, 01:50:50 PM
Hey Pete!

Great Work!

Feel free to post photo's of any of this rebuild....that's why we have a restoration section....and cleaning/painting and "dealing" with the defects is what it's all about

Dave
Title: Re: Another Simplex Refurbishment
Post by: arnoldb on August 24, 2012, 06:10:41 PM
 :NotWorthy: Looks great Pete, and runs very nicely  :ThumbsUp:

Kind regards, Arnold
Title: Re: Another Simplex Refurbishment
Post by: doubletop on August 25, 2012, 09:58:21 AM
Thanks guys, its coming along unfortunatley Dave I haven't many photos of making bits and bobs and actualy I'm a bit further on that the video's while I was waiting for parts to be delivered I spent my cleaning rubbing down priming and re-painting to the point that all the plate work is painted ready for re-assembly. So today I thought I'd do a trail fit.

Before

(http://i.imgur.com/lfCSNW0.jpg)


After
(http://i.imgur.com/SK2pLAi.jpg)

Before
(http://i.imgur.com/4lkZ4bY.jpg)

After
(http://i.imgur.com/eZHRNyU.jpg)

Before
(http://i.imgur.com/vijyIIT.jpg)

After
(http://i.imgur.com/jwZCdGr.jpg)

As I said a trail fit with barely any fixings holding it together, encouraging things was all the plate work holes lined up perfectly so nothing out of alignment since the strip down.  Still plenty to be done with rework on all the plumbing, drain cocks, brakes, ash pan needs some work. That's tomorrow

Pete



Title: Re: Another Simplex Refurbishment
Post by: steamer on August 25, 2012, 12:13:31 PM
No worries Pete!   "run what ya brung!"

We'll watch!

Looks Great!

Dave
Title: Re: Another Simplex Refurbishment
Post by: sbwhart on August 25, 2012, 12:55:35 PM
Looking good Pete  :whoohoo: :whoohoo: :whoohoo: :whoohoo:

I like the change in colour.

What paint did you settle for in the end ?.

Stew
Title: Re: Another Simplex Refurbishment
Post by: zeeprogrammer on August 25, 2012, 01:19:14 PM
That's just looking great.

There must be a great feeling of satisfaction doing a restoration.
Title: Re: Another Simplex Refurbishment
Post by: doubletop on August 26, 2012, 08:40:51 AM
Dave

Thanks I'm quite pleased with the results myself

Carl

Doing a refurb is the quick way to getting a running loco. My Rob Roy is fun to drive but it won?t pull much and the Northumbrian is just a toy. I wanted something I can play with on sunny days rather than waiting while I spend five years building something from scratch. I can now play and get that long term project underway

Stew

On the painting

Frames

The frames I?ve done with Hammerite Smooth. I used to use it years ago and had great coverage and durability. This time I used spray cans and the jury is out on the results. The paint didn?t apply as well as I expected and it exhibits thinning at the sharp edges, it also doesn?t like loctite. On my Rob Roy I had the frames powder coated, If I do a full strip down again I may go for the powder coating. When I did the Rob Roy the powder coaters gave me high temp masking tape to mask off all those places where dimensions need to be maintained, cylinder mounting faces, axle boxes, motion plate etc.

Hot spots

Smoke box, saddle, smokebox door, backhead are all done in high temp engine, barbecue paint and baked to cure in the barbecue. I couldn?t get my smokebox off the boiler and wasn?t going to heavy it, so the baking of the whole boiler didn?t go to well. If its not baked any solvent, oil will remove the paint. I?ll redo in situ and let the first firing do the baking for me.

Wheels and Platework

Where already painted I rubbed down with 400 wet/dry primed with primer filler and sprayed with epoxy enamel. I stumbled across epoxy enamel in the auto store and then found it available everywhere. It goes on great and is a great finish. It can go on bare metal with no primer, but I didn?t do that. On another forum I ended up in a conversation with Chris Vine (book - How not to paint a loco) he advise that epoxy enamel can go brown under heat but another forum member said that a number of members in his club have used epoxy enamel without any problems. We?ll see. I?ve used Deep Brunswick Green.

Panels where paint was coming off were stripped and primed with etch primer and then re-painted in epoxy enamel

In all cases 3 coats were applied, rubbing down between each coat. After the final coat, auto sprayer style, I baked the end result in the barbecue at about 200degF just to harden the paint.

Lines

I found I had a Buegler lining tool http://www.beugler.com  (http://www.beugler.com)in my kit, it was brand new and unused, my dad must have bought it for something. Anyway I thought I?d give it a go and after a while got the hang of it

(http://i.imgur.com/TeYKUhv.jpg)

The smears are were I had washed loco before taking the pics and the flash showed them up

Hope that helps

Pete
Title: Re: Another Simplex Refurbishment
Post by: sbwhart on August 26, 2012, 09:41:46 AM
Hi Pete

Thanks for the heads up on the painting, I,m going to use hammerite smooth same as you on the frames, I have some high temp auto paint for the hot spots got it from halfords, the rest I'll just use car body paint mine is going to be an all black job, I'm going to mark it up as a WD loco the military ran quite a few locos at one time and I though it would be unusual to have one in that livery as the guys at the club running simplexes seemed to have bagged on the usual livery skeems LNWR:- BR:- GWR etc.

I'm not particularly after a sooper paint job I just want something that will run well and pull a uselfull load of passengers.

Stew


Title: Re: Another Simplex Refurbishment
Post by: doubletop on August 26, 2012, 10:24:31 AM
Hi Pete


I'm not particularly after a sooper paint job I just want something that will run well and pull a uselfull load of passengers.

Stew

I'm with you this is a run-about for playing, however seeing your other work your "not sooper" paint job will no doubt look like it's just out of the works.

I'm going GWR, hence the window change,  I come from down south and used to go to school on GWR and the last days of steam. Green because I did the Rob Roy in black.

Pete
Title: Re: Another Simplex Refurbishment
Post by: ozzie46 on August 26, 2012, 01:54:12 PM


  She's looking real nice Pete. I hope mine looks half as good when I'm done.

  Ron
Title: Re: Another Simplex Refurbishment
Post by: doubletop on August 27, 2012, 08:59:32 AM
Ron

I'm sure yours will look as good if not better. The other thing with yours you'll have made it yourself and no shortcuts like me.

regards

Pete
Title: Re: Another Simplex Refurbishment
Post by: steamer on August 27, 2012, 10:40:43 AM
Looks great Pete!   Any tips on the pin stripping?  Want to do a thread?

Not something that is done everyday.....If you have a few photo's  go ahead and post them....otherwise, if you can manage the time, and throw a post together on the subject, Id bet more than a few of us would love the schooling!  I couldn't paint a straight line to save my life! :wallbang:

Dave

Title: Re: Another Simplex Refurbishment
Post by: Maryak on August 27, 2012, 01:16:27 PM
  I couldn't paint a straight line to save my life! :wallbang:

Dave

Ha, even I can do that, lots of very short ones joined together at angles various. Fly excreta springs to mind.

Nest Regards
Bob
Title: Re: Another Simplex Refurbishment
Post by: doubletop on August 28, 2012, 11:40:32 AM
Dave/Bob

I don't think finding you had a tool in the cupboard, reading the instructions bunging some paint in it and giving it a go qualifies me as an expert. However....

Details here http://www.beugler.com/about-2/ (http://www.beugler.com/about-2/)

and as with anything these days you don't really need to read the manual because somebody has already done it for you and posted videos on YouTube. I just did what they suggested

http://www.youtube.com/watch?v=inGo2ZF4qsw

http://www.youtube.com/watch?v=pyvh1R6jClg

http://www.youtube.com/watch?v=eWQs6HKPTzI

http://www.youtube.com/watch?v=jBXzAlM5iyk


OK I just did the simplest version, no curves. Just two parallel lines of masking tape and a ruler as a guide. start on one tape, across the job and finish on the other tape. Allow to dry, remove the tapes and then tape up to the edge of the lines you've just done and do the other two lines to complete the rectangle.

It proved so easy I came home from work and had the first sets done before dinner and went out after dinner and finished the job off.

Pete

Title: Re: Another Simplex Refurbishment
Post by: doubletop on August 30, 2012, 11:10:48 AM
Its plumbing time and sorting out this spaghetti. Some of it has spent some time in the pickle to clean it up

(http://i.imgur.com/Fdd6IN7.jpg)

You can see that the cones are pretty well worn. I'm assuming they were loose and the shagged motion shook them so much they wore away.

(http://i.imgur.com/XWe4e99.jpg)

Replacement cones were already on order from Polly model. Why don't I buy them locally? Price; and they don't take that much longer to get here.

---------------- a few days later.

Cones have arrived and I've started on the pipework. I'm glad I did, some of the cones were barely on the end of the pipes, a quick blast of the torch and they fell off. Others demonstrated to me what de-zincification is about. They just broke up when I gripped them in the pliers to remove them.

I'll do some pics over the weekend

Pete
Title: Re: Another Simplex Refurbishment
Post by: steamer on August 30, 2012, 11:26:57 AM
I can tell you Pete,  those connections are vital!   I'm glad your doing them up right!    With the yearly tear down and then replumb for winter on my boat...I end up a bucket of spaghetti too...and I have to be careful of the cones so I don't damage them.

Dave
Title: Re: Another Simplex Refurbishment
Post by: doubletop on August 30, 2012, 11:35:14 AM
Dave

Like Stew's re-build, do it once, do it right. I don't want to go back and take it all apart for something I could have dealt with. That said I fully expect it will all come apart again for something, but I'm not fazed about doing that either.

Pete
Title: Re: Another Simplex Refurbishment
Post by: steamer on August 30, 2012, 11:35:54 AM
And OH CRAP!   You posted on the pin striping!   Thankyou!

THATS how you do it.....!   


I will watch and learn!

Dave
Title: Re: Another Simplex Refurbishment
Post by: doubletop on August 30, 2012, 11:56:54 AM
No problem, but as you can see no special skills required apart from being able to read. After I posted these links I realised I'd done it the wrong way. I wondered why I was getting blobs of paint. I should have pulled rather than pushed the tool.

Anyway I also find I have a pic of the start of the plumbing.

(http://i.imgur.com/SEtaZlA.jpg)

I've also fixed the ashpan. the drop door was hanging by a thread. no doubt a result of it dropping whilst in motion and getting ripped off. Anyway the end plate with the hinges is fixed with some stainless screws which made it easy to remake and silver solder the hing pivots in place.

Note the ash pan in the base Simplex can't be removed without taking out the boiler. Something Martin Evans acknowledged for the Super Simplex and re-designed. What you do in an emergency when you would normally drop the fire I haven't worked out yet, and I imagine you have to finish your day's running a tad earlier than everybody else to let the fire go down.

Pete
Title: Re: Another Simplex Refurbishment
Post by: zeeprogrammer on August 30, 2012, 12:31:52 PM
That looks sharp.

Question...near the bottom of the picture, center, looks like a spring clip against a hex nut and the hex nut looks like it has two dimples (holes?). Does the spring clip keep the nut from rotating and are the dimples (or holes?) for oiling? Thanks.
Title: Re: Another Simplex Refurbishment
Post by: doubletop on August 31, 2012, 09:46:46 AM
Carl

It's to stop the gland nut from coming loose. If the gland nut was fully tightened the pump wouldn't work. I assume it is done this way rather than using a lock screw is the nut is not very accessible and so can be adjusted without having to undo anything. The spring just pops out of the way

hope that helps\

Pete
Title: Re: Another Simplex Refurbishment
Post by: sbwhart on August 31, 2012, 01:26:31 PM
I'm glad yoy asked that ? Carl  I've forgotten add that feature to my pump.

Looking good Pete.

Stew
Title: Re: Another Simplex Refurbishment
Post by: doubletop on August 31, 2012, 09:34:38 PM
Thanks Stew

Track working party today to get the swing arm and feeder tracks in so not much is going to happen on the loco. It all re-assembly really so I am getting very close to a first steaming maybe not this weekend as the weather is likely to be crap tomorrow.

It's touch and go which gets finished first the new track or the loco. You'll understand I want it ready for the formal opening.

Pete
Title: Re: Another Simplex Refurbishment
Post by: doubletop on September 03, 2012, 11:06:02 AM
Got the plumbing spaghetti sorted, or at least rearranged to some degree

(http://i.imgur.com/YOlEzSd.jpg)

(The pieces of steel under the axle box keeper plates sets the suspension at running height so I can run it with its legs dangling) in free space.)

and the backhead, a bit tidier than it was.

(http://i.imgur.com/gboekwu.jpg)

And did a bit more to the bling

(http://i.imgur.com/sWajaCa.jpg)

The flash doesn't do the colour any favours it washes it our a bit. Its a deep Brunswick Green that I'm quite pleased with.

Next step is a steaming and that always ends up making a mess of everything so its unlikely to look this clean and tidy again. But it will have more of a lived in look.

Pete
Title: Re: Another Simplex Refurbishment
Post by: zeeprogrammer on September 03, 2012, 01:40:09 PM
Looks excellent.
Really gives a feeling for the amount of work needed.
Enjoy the steaming!
Title: Re: Another Simplex Refurbishment
Post by: steamer on September 03, 2012, 01:45:30 PM
Looks great Pete!

Well done!   video?.........

Dave
Title: Re: Another Simplex Refurbishment
Post by: doubletop on September 04, 2012, 10:34:40 AM
Thanks guys

Carl; just like eating an elephant one piece at a time and before you know it you are there. OK elephants are off the menu these days but you know what I mean.

Dave; Of course they'll be a video when I get it going but not until the weekend at the earliest.

Tonight I started the standard (column) for the brakes, it didn't have any but when I did the frames I drilled for the hanging points and made some of the parts, while waiting for deliveries. Now I've got it back together and waiting for the weekend I can make those other parts for the brakes. No photos though, I've just got in and I'm not going out again, its dark.

Club night tomorrow

Pete

Title: Re: Another Simplex Refurbishment
Post by: doubletop on September 06, 2012, 10:24:55 AM
You may recall Stew made 6 drain cocks over here http://www.modelenginemaker.com/index.php/topic,240.0.html (http://www.modelenginemaker.com/index.php/topic,240.0.html) and offered the two spares to a good home. Well they arrived in NZ today and it didn't take long to get them fitted.

(http://i.imgur.com/MLVDlK6.jpg)

Thanks a lot Stew the are great. Hopefully the weather will hold out for the weekend and I'll be able to try them on my first steaming and give you a report.

That got me out to the workshop so I was able to do a bit more of the brakes. I'd made the standard on Tuesday evening and the hand wheel and shaft tonight.

(http://i.imgur.com/coXOTL7.jpg)

Pete

Title: Re: Another Simplex Refurbishment
Post by: doubletop on September 11, 2012, 07:15:32 AM
I'm afraid the weather has been a bit iffy so no first steaming yet. So I've been locked away making parts for the brakes which it didn't have.

(http://i.imgur.com/ju826xE.jpg)

The base Simplex wasn't designed with brakes the drawings are for the Super Simplex The brackets bottom left are to convert the Simplex frames to provide the correct location point for the bushes for the cross shaft. Now I've just got to get the linkage rods and shoes made.

Before somebody asks I've made everything for brakes on all 6 wheels but getting the suspension links and shoes onto the front wheels may be a problem as space is tight on the Simplex so it may just end up with 4 wheel brakes. The Super has longer frames.

Pete
Title: Re: Another Simplex Refurbishment
Post by: steamer on September 11, 2012, 09:18:38 AM
NICE!  Looks like this is coming along very well Pete...4 is still greater than ZERO.....

Dave
Title: Re: Another Simplex Refurbishment
Post by: doubletop on September 11, 2012, 09:31:42 AM
Thanks Dave

I've just been to the workshop to see about making a start on the installation. It looks like a bit of re-routing of the plumbing is required. Not something to be tackled on a Tuesday evening so I shut everything down and came back in. I'll save that job for the weekend.

 Pete
Title: Re: Another Simplex Refurbishment
Post by: zeeprogrammer on September 11, 2012, 12:17:20 PM
No brakes?! Just wait for lack of water or fire?  ;D
Sorry to hear about the weather.
Title: Re: Another Simplex Refurbishment
Post by: Bearcar1 on September 11, 2012, 03:14:09 PM
Bummer about the weather Pete, but watching your progress, it seems that you have been making the most of it. Soon the clouds will part and the skies will clear and then the air can be filled with plumes of steam and smoke. YOUSA!!!!  :pinkelephant:


BC1
Jim
Title: Re: Another Simplex Refurbishment
Post by: Jo on September 11, 2012, 08:21:25 PM

......there may be a problem as space is tight on the Simplex so it may just end up with 4 wheel brakes. The Super has longer frames.

Pete

My Super may have longer frames but be warned as designed the leading shoes hit the rear cylinder covers   :rant:

Jo
Title: Re: Another Simplex Refurbishment
Post by: doubletop on September 12, 2012, 07:59:36 AM
Carl/Jim

Look at the weather as a positive, I've now got time to do things I may well have skipped over and then never got around too as I would be too busy playing trains.

Jo

I'm not sure of the chronology of the two but the Rob Roy and Simplex just look to me like clones of each other but with different valve gear. My Rob Roy has the front brakes squeezed in with slim line hangers, relieved to clear the covers, so I thought I may end up doing something similar here. I've included all 6 pivot points but, as Dave says, 4 brakes are better than non and the front set most probably won't get fitted.

regards

Pete
Title: Re: Another Simplex Refurbishment
Post by: Jo on September 12, 2012, 08:45:54 AM
Very likely, most of Martin Errors Evans designs follow the same design principals as originally laid down by LBSC. So they will all share many characteristics and design corrections :disappointed:/improvements :D will be interchangable.

Jo
Title: Re: Another Simplex Refurbishment
Post by: doubletop on September 16, 2012, 09:40:49 AM
Jo

How right you are. I was at the club today and had reason to go into the storeroom. I picked up an old ME from the shelf  from 1951, randomly opened it and there were the parts for the brakes of I'm making. I think they were for a Tich.

Despite the forecast for a wet weekend, this morning was fine so time to wheel the out the loco and show it the sun and get some more pictures. No time for steaming though as I was on track duty today, it was raining after an hour so we didn't run for long. Hence the opportunity to skim through old ME's

(http://i.imgur.com/L9npUWF.jpg)

I did get a chance to fill it with water and do a preliminary pressure check using the hand pump. That was after I'd done up the unions I had only done finger tight :???: . Got those sorted and found a few minor leaks which needed some work, but nothing major.

I've also started to fit the brakes, here's the standard installed

(http://i.imgur.com/f133ERq.jpg)

And the cross shaft and die nut.

(http://i.imgur.com/vBeiunv.jpg)

One thing I have discovered, the frame spacing on the Super Simplex is 4 1/8" but the standard Simplex is 4 3/16"  this means the cross beams I've made are 1/16" too short. Easily fixed, I'll replace the stubs with something slightly longer and put a washer behind each brake hanger.

On the last photo you'll also notice the pipework for the water feed to the axle pump runs between the wheels and springs. This means the pipework needs moving or the brake hangers will need to be longer. Moving the pipework is going to be a problem as I don't want to run it up and over the wheels, under the running boards, as that could cause an air lock. Making the brake hangers longer will limit the range of movement slightly and may have clearance problems being 1/4" longer. I'll come up with something.

Pete
Title: Re: Another Simplex Refurbishment
Post by: doubletop on September 23, 2012, 10:09:50 AM
Well today was the day. We?ve had a fine weekend so no excuses so it was time to get some water, oil and fire into the thing to see what happens.

First thing was to fill it with water, and use the hand pump to fill the boiler all the way to the top, holding the whistle valve open and pump until water came out of the whistle. Making sure the regulator and blower valve are closed,aa couple of extra stokes on the hand pump and the pressure gauge can be used for an impromptu pressure test while doing a leak check. A small leak from a union on the blower was quickly fixed. Then I drained down the boiler to get the water level right. Lubricated everything and was ready to go.

Raising steam was pretty much drama free. However it wouldn?t start when I opened the regulator. I suspected a hydraulic lock so removed the drain cocks and it eventually started. Put the drain cocks back in and it ran OK from then on. I must have primed the system doing the leak check. (see the muck on the smokebox)

http://www.youtube.com/watch?v=xF7uVoRkTqI

There?s a bit of a knock in there but the occasional rattling noise is the clacks ?clacking? you?ll see me adjusting the bypass at some point and can hear them coming on and off.

I did try the drain cocks Stew had made me but with sorting out the priming they got removed and removing variables I put the manual drain cocks back in. I?ll give them a better go next time.

And I?ve found a problem with the work trolley. The wheels are urethane or some such plastic. When the safeties blow the whole loco gets a static charge!!  I got a shock each time I went to adjust something, this happened every time the safeties went, so I wasn't imagining it. The trolley needs an earth strap or something.

Regards

Pete

Title: Re: Another Simplex Refurbishment
Post by: zeeprogrammer on September 23, 2012, 12:32:00 PM
Well that's just beautiful Pete. And Congratulations!
The pic of the cab was astounding to me...as well as the rest of it.
Very nice.
Title: Re: Another Simplex Refurbishment
Post by: ozzie46 on September 23, 2012, 02:36:18 PM



  Lovely Pete. Absolutely musical.   :whoohoo: :whoohoo: :whoohoo:

  Ron
Title: Re: Another Simplex Refurbishment
Post by: sbwhart on September 23, 2012, 04:29:01 PM
 :whoohoo: :whoohoo: :whoohoo: :whoohoo: :whoohoo:

We have a steam Loco

Nice work Pete next thing:- on the track with a few pasengers behind a beaming driver.

 :ROFL: :ROFL: :Lol: :Lol:

Stew
Title: Re: Another Simplex Refurbishment
Post by: doubletop on September 25, 2012, 08:31:32 PM
Carl, Ron, Stew

Thanks for your good wishes and apologies for my tardy response. I'm attending a conference at the moment which results in later nights than normal. You know how these things go.

Back to normal at the end of today

regards

Pete
Title: Re: Another Simplex Refurbishment
Post by: arnoldb on September 26, 2012, 06:16:01 PM
She runs like a champ Pete  :ThumbsUp: - Well done!

Nary a chuff on no-load - I'm looking forward to see and hear her when on the rails for the first time; that should bring the chuff out  ;D

Kind regards, Arnold
Title: Re: Another Simplex Refurbishment
Post by: steamer on September 27, 2012, 01:52:11 AM
Sounds Great from here Pete....you need to put her to work!    A good load makes for some nice stack "talk"

Dave
Title: Re: Another Simplex Refurbishment
Post by: doubletop on September 27, 2012, 11:35:24 AM
Thanks Arnold and Dave

Hopefully well get another nice Sunday and it will be down the club for the steam test and certification. Then wait for somewhere to run it. The track re-build is complete except for the swing arm and now the access track from the steaming bays. A suggestion "lets re-align it" ended up with virtually complete removal ready for a re-build on the basis of getting it right rather than wishing later that we had.

regards all

Pete
Title: Re: Another Simplex Refurbishment
Post by: doubletop on October 11, 2012, 09:47:10 AM
I 've finally got the brakes finished. I been messing around half heartedly trying to find something to use for the brake blocks. I didn't have any CI to make a ring in the time honored way. I was reluctant to have to hack them out of solid and make them one at a time so to be honest I'd been stalling for weeks . It came to the point that I had to do something so rummaged around looking for inspiration I found I  had some 1.5" hex bar that allowed me to cut some 3/8" slices and face them to thickness in the lathe. Cut them in half and get two brake blocks out of each slice. I was then in two minds how to cut the radius, in the lathe or in the mill. They are too small for the 200mm lathe faceplate and I couldn't work out how to hold them in the milling vice so I could use the fly cutter vertical in the mill. Then I had an inspiration, my milling head will go through 90deg and so will my milling vice, so simple and four shoes in one go.

(http://i.imgur.com/fEnCQP9.jpg)
 
The home made flycutter looks a bit ungainly in the ER32 collet but it does the job. The whole set of blocks from start to finish was 4 hours max, a couple of evenings really.

So a bit of work to put all the parts together.

(http://i.imgur.com/gRyPu6u.jpg)

(http://i.imgur.com/s8EwamF.jpg)

(http://i.imgur.com/lQXajG7.jpg)
 
You'll notice a bit of rerouting of the p;plumbing was required to get the coupling rods in as the exiting pipework ran just where they needed to go.

(http://i.imgur.com/YOlEzSd.jpg)

That's it for now. I've arranged with the club inspector for the steam test and certification to be done on the next fine Sunday. Unfortunately it doesn't look like its going to be this weekend.

regards
Pete
Title: Re: Another Simplex Refurbishment
Post by: Jo on October 11, 2012, 10:19:32 AM
Then I had an inspiration, my milling head will go through 90deg and so will my milling vice, so simple and four shoes in one go.

 8) I hadn't thought of that. My Prazimat mill nose takes the chucks and faceplates off the Hobbymat lathe. :whoohoo:
Wow, what a diameter could be turned if I mounted a tool post on the milling table.

Jo

Title: Re: Another Simplex Refurbishment
Post by: doubletop on October 12, 2012, 10:09:46 AM
Jo

Yes, before I got a decent lathe I'd that in the past, . This is making some rollers to try out my Rob Roy

(http://i.imgur.com/vUYLnVC.jpg)

Though I didn't need to put the spindle horizontal.

Even with the mill going down to 90rpm putting something really big in the chuck could be a bit hairy.

Pete
Title: Re: Another Simplex Refurbishment
Post by: doubletop on October 14, 2012, 07:58:10 AM
Big day today, the weather cleared up so I rang the boiler inspector to see if he was going to the track.

He was so the loco got packed into the car and off we went for the boiler certification. All good, so I'm ready to go. Unfortunately at the moment there's no access from the steaming bays to the 5" gauge track as its still part of the re-build, so we had to make to with it running on blocks

http://www.youtube.com/watch?v=mT4EUHcKIuw

Happy chappy

Pete
Title: Re: Another Simplex Refurbishment
Post by: sbwhart on October 14, 2012, 08:07:39 AM
 :pinkelephant: :pinkelephant: :pinkelephant: :pinkelephant: :pinkelephant:

:whoohoo: :whoohoo: :whoohoo: :whoohoo: :whoohoo:

Great stuff Pete I bet you can't wait for the track to be cleared.

Stew
Title: Re: Another Simplex Refurbishment
Post by: Jo on October 14, 2012, 08:26:46 AM
Brilliant,  :cheers:

Jo
Title: Re: Another Simplex Refurbishment
Post by: doubletop on October 14, 2012, 08:48:59 AM
Thanks guys, my aim had been to get it running for the summer. The track really isn't that far from being finished. If there hadn't been a bit of 'scope creep' it would have been done. But I can't really complain, it was one of my off-hand comments that got the access track re-aligned. It ran too close to one of the storage units and was a real PITA when moving from the steaming bays to the raised track.

As always with these things the 'to do' list never gets completed so I've got a few odd jobs lined up already, More cosmetic and functional changes than major machining, like make a new shovel. Those in the know were looking at mine a bit quizzically when somebody handed me another one and said 'try this' it was ten times better, I could get coal in quicker so easier to maintain steam.

Pete

Title: Re: Another Simplex Refurbishment
Post by: steamer on October 14, 2012, 01:02:45 PM
Nice Job Pete!

Dave
Title: Re: Another Simplex Refurbishment
Post by: ozzie46 on October 14, 2012, 01:25:24 PM


   Way to go Pete!!  Looks and sounds great.

  Ron
Title: Re: Another Simplex Refurbishment
Post by: vcutajar on October 14, 2012, 01:33:05 PM
Congratulations Pete.

Vince
Title: Re: Another Simplex Refurbishment
Post by: zeeprogrammer on October 14, 2012, 02:02:25 PM
Congratulations Pete! Looks fantastic. Love the whistle!
Anxiously awaiting a video of the track run.
Title: Re: Another Simplex Refurbishment
Post by: doubletop on October 15, 2012, 11:11:31 AM
Dave, Ron, Vince, Carl

Thanks for the good wishes guys. This evening I finished modifying the access rail to get the loco from the car to the steaming bay and the replacement shovel got half built, so the jobs list is being worked through.

regards

Pete
Title: Re: Another Simplex Refurbishment
Post by: doubletop on October 16, 2012, 09:28:58 AM
The shovel wasn't too much effort to make.

(http://i.imgur.com/INexlhM.jpg)

I didn't have any stainless so made do with 1mm brass sheet and some 3/16" steel rod I had lying around.

SWMBO is now asking for some kitchen utensils!! Despite MBO status I may just have to ignore that for now

Pete
Title: Re: Another Simplex Refurbishment
Post by: Jo on October 16, 2012, 09:56:55 AM
Ho boy I can see why you would have had problems with that original shovel.  :Doh:

I like your round handle, it should be stronger than the original you borrowed :ThumbsUp:, did you think where you are going to store her whilst running?

Jo
Title: Re: Another Simplex Refurbishment
Post by: doubletop on October 16, 2012, 10:42:28 AM
Jo

Thanks; There's plenty of room in the bunker above the well tank. My Simplex was made over 1/2" wider and 3" longer that Martin Evans drawings so the bunker is plenty big enough for coal and bits and bobs.

(http://i.imgur.com/f133ERq.jpg)

Also my riding trolley, although fitted for gas for my Rob Roy the gauge/valve panel comes out pretty quickly for additional handy storage.

(http://i.imgur.com/9Z3einD.jpg)

It's also rigged for 12v with an additional 2 Litre water tank and pump  ;D

Pete
Title: Re: Another Simplex Refurbishment
Post by: zeeprogrammer on October 16, 2012, 11:55:29 AM
I can never get enough of your pics of the loco. Just beautiful.

Despite MBO status I may just have to ignore that for now

Good luck with that.  ;D
Title: Re: Another Simplex Refurbishment
Post by: NickG on October 16, 2012, 04:04:27 PM
Fantastic job again Pete  :ThumbsUp:
Title: Re: Another Simplex Refurbishment
Post by: arnoldb on October 16, 2012, 08:07:40 PM
 :whoohoo: Congratulations Pete  :whoohoo:
Can't wait for the first track run video  ;D

... Just tell SWMBO you don't have food-grade silver solder   :paranoia:

Kind regards, Arnold
Title: Re: Another Simplex Refurbishment
Post by: doubletop on October 17, 2012, 10:15:11 AM
Carl, Nick Arnold

Thanks for your support. I've also passed your comments on to SWMBO with no negative reaction at the moment. I take the view get the pain over as soon as you can then you can get back to normal as sooner.

regards

Pete
Title: Re: Another Simplex Refurbishment
Post by: doubletop on November 04, 2012, 09:11:20 AM
It was a nice day so I went to the track today to do a "logistics dry run". When it comes to the day of the first proper run you have to be ready.


And that's all I can do at the moment however the point of this exercise was to make sure I'm ready when the new track is completed, and it isn't far off

(http://hvmes.com/new_track/Raised%20Track%201.11.jpg)

A couple of weeks, end of the month at the latest, easily ready for the start of summer

Pete
Title: Re: Another Simplex Refurbishment
Post by: zeeprogrammer on November 04, 2012, 12:20:37 PM
Very much looking forward to it Pete.

Still strikes me odd that people are getting ready for summer while we're getting ready for winter.
Title: Re: Another Simplex Refurbishment
Post by: steamer on November 04, 2012, 01:24:19 PM
Very much looking forward to it Pete.

Still strikes me odd that people are getting ready for summer while we're getting ready for winter.


Me Too!!!!!

Dave
Title: Re: Another Simplex Refurbishment
Post by: ScroungerLee on November 04, 2012, 02:15:16 PM
Perhaps I need a second house in NZ.  That would require a separate shop. Hmmm.

Lee
Title: Re: Another Simplex Refurbishment
Post by: steamer on November 04, 2012, 02:25:34 PM
Perhaps I need a second house in NZ.  That would require a separate shop. Hmmm.

Lee


Nope....just need to get adopted! :ROFL:
Title: Re: Another Simplex Refurbishment
Post by: doubletop on November 05, 2012, 08:39:08 AM
Well guys you can't have it both ways, unless you find yourself a place in the southern hemisphere you've had your summer now its our turn :D Or, as we are actually ahead of you in time, we've had our winter now its your turn. :(  Depends if you are of the glass half full or half empty disposition.

 I'm from the northern hemisphere and still struggle a little bit with summer at Christmas time. Christmas shopping in shorts and tee shirts and Christmas day when it is supposed to be cold. One solution is turn the air con to full cold, put on some warm clothing, light the fire and enjoy Christmas day. Then get over it and the next day have some people around get a barbecue going and enjoy a few cold beers out in the sun.

Back to model engineering; The club archivist had taken some photos yesterday. The ground level track is still accessible from the steaming bays and there is a short 5" gauge section. Actually there's a pretty long 5" gauge section but an upgrade of the 7.25" gauge track omitted to complete the  points so you can't get far. Anyway I took it for a run up and down. As I hadn't anticipated doing this my riding trolley wasn't set up for ground level running so I had to resort to shunting up and down driving from the track-side.

(http://i.imgur.com/VU2uiqt.jpg)

Its getting close Carl

Pete
Title: Re: Another Simplex Refurbishment
Post by: sbwhart on November 05, 2012, 09:12:16 AM
Blimey Pete I bet your chomping at the bit to get it running arround that track.

It's all looking good.

Stew
Title: Re: Another Simplex Refurbishment
Post by: doubletop on November 05, 2012, 09:47:22 AM
Stew

That's why I ran it down to the GL track, it was there so why not? It did identify a few more things that needed doing. One good thing about having to wait is you get those jobs done that you may have let go.

One of the things was drain cocks and I've been meaning to give you an update on those you kindly sent over. I tried them and couldn't get them to work consistently. Or that's what I thought. The problem I had was the uncertainty that they were doing what was expected of them at any point, open when they needed to drain the cylinders or closed when running. When ever I tried to run from cold I'd get hydraulic lock and couldn't clear it (it didn't occur to me at the time to stick something up the drain hole) Then when I got it going they seemed to be venting. So rather than work it out, being a bit impatient and having time on my hands I thought I'd give some steam drain cocks a go as then I'd  know when on was on and off was off. Guess what, similar problem. So now I've got two sets of drain cocks (actually three sets, if the 4 individual manual cocks are included) each system having their own issues, which I need to work through.

The point being there is probably absolutely nothing wrong with the pair you sent over, I just didn't persevere enough to get the level of confidence they were doing what they should and now I've too many variables to work with to come to any conclusion and could well end up using your drain cocks and wondering what I had thought was wrong in the first place.

And that's made me think; I could well re-fit the auto cocks to one side and the steam cocks to the other and compare both. With the loco inverted on the stand its only a 5min job to fit them.

regards

Pete
Title: Re: Another Simplex Refurbishment
Post by: doubletop on December 09, 2012, 08:06:29 AM
The rebuild of the raised track is all but complete,

(http://i.imgur.com/924wRSv.jpg)

We had really nice day today so it had to be an opportunity to try a run, although I had always been of the view that privilege was to go to the key people who led the track build. That aside, I went out there anyway to find the project manager and the guy who did all the welding, (over 6000 welds), were there. One of them had his camera in the hope that somebody would turn up and they wer both encouraging me to give it a go. 'nuff said onto the steaming bay and get ready.

What they didn't tell me was the swing arm still needed some work so was out of action. Undeterred we manhandled the steaming loco from the feeder line onto the track

(http://i.imgur.com/LYjsjnp.jpg)

OK, I could only do loops up to the swing arm and then reverse all the way back for another go. It went better than I expected, starting off, sight glass full,  steamed up to 90psi and safety blowing and the pump bypass closed I was doing full laps with the safety blowing all the way.

Hopefully, next time, the problem with the swing arm will be rectified and I'll get a video for you.

Pete
Title: Re: Another Simplex Refurbishment
Post by: doubletop on December 26, 2012, 09:03:26 AM
The track got finished and the first Sunday I went out for a run. I've been a bit tardy in getting this video posted as my cameraman had a few problems so we went back  last week for another go. It hauls passengers without any problems but I think I do need to do some more work on the valve timing as its a bit asymmetric under load. But all in all I'm happy with the results so far.


http://www.youtube.com/watch?v=mwZrr-4z3o8

regards

Pete
Title: Re: Another Simplex Refurbishment
Post by: zeeprogrammer on December 26, 2012, 11:14:05 AM
That is so cool Pete. Thanks for the video.
That has to be a cool feeling to run it and give enjoyment to others.
Title: Re: Another Simplex Refurbishment
Post by: doubletop on December 26, 2012, 11:27:22 AM
Carl

Seasons greetings

I had no idea what it was capable of until I hitched up a wagon and people got on for the ride. We'll all know about steam but you'd think these little kids would have no idea, but its amazing what they come up with. No doubt a result of the "Thomas The Tank Engine" and similar stories. Even the really small ones see there is something different with these locos than the contemporary diesel/electric locos and will wait patiently for a ride.

And it attracts more public interest contributing to club funds

Pete
Title: Re: Another Simplex Refurbishment
Post by: steamer on December 26, 2012, 12:11:44 PM
Congrats Pete!   Well Done! and thanks for bringing us along!
That engine scoots!
Dave
Title: Re: Another Simplex Refurbishment
Post by: doubletop on December 28, 2012, 10:35:24 AM
Thanks Dave

Apologies for the tardy reply. Been a busy few days but normality is returning and made it to the shop today. Not that I did much....

Pete
Title: Re: Another Simplex Refurbishment
Post by: sbwhart on December 28, 2012, 10:53:25 AM
Great run Pete.

 :cartwheel: :cartwheel: :cartwheel:

Thats certainly given me something to aim for in the new year, all the best

Stew
Title: Re: Another Simplex Refurbishment
Post by: doubletop on December 29, 2012, 12:25:36 AM
Thanks Stew

I'm pleased with it but as always there's something more that can be done.

Now you've finished the Dake is it full steam ahead on the Simplex or do you have another build in the offing (have I missed it?)

Also updated your Drain Cox (sic) thread

Pete
Title: Re: Another Simplex Refurbishment
Post by: sbwhart on December 29, 2012, 08:22:01 AM
Its full steam a head with the Simplex, I've told our club charman that he is to ban me if I don't get it running for the summer.

I do have a couple of other project on the drawing board, but they definatly won't be started until the simplex is running.

Stew
Title: Re: Another Simplex Refurbishment
Post by: doubletop on July 13, 2013, 06:46:37 AM
The original Simplex didnít allow the grate and ash-pan to be dropped. A bit of a problem in an emergency and something Martin Evans acknowledged and fixed with the Super Simplex by modifying the foundation ring and ash pan.

This has been something Iíve wanted to sort next time the boiler came out. Itís winter here in NZ so an opportunity to do something about it.

I had wondered why I wasnít steaming too well last time out, this is the clinker I found in the firebox.

(http://i.imgur.com/MeYGX4V.jpg)

Rather than mess with the existing grate, and regret it, I looked around for a replacement to play with. I had some idea of making a split grate and allowing the front section to come out with the drop door on the ash pan. Then I found Blackgates did this stainless grate that they just cut to size.

(http://i.imgur.com/yjuG184.jpg)

Perfect. The cross bars allow the middle bar to be used as a pivot. This is what I came up with.

(http://i.imgur.com/dT2Xsno.jpg)

Some tabs applied to the drop door hold the grate in place

(http://i.imgur.com/HeSFFkY.jpg)

When the door opens the grate pivots and tips forward

(http://i.imgur.com/OQ3N4wt.jpg)

And from underneath

(http://i.imgur.com/HfCHzL4.jpg)

Now Iíll be able to drop the fire and clean out the firebox at the end of the run so clinker doesnít build up.

Hope that helps somebody.

Pete
Title: Re: Another Simplex Refurbishment
Post by: sbwhart on July 13, 2013, 12:50:19 PM
Thanks for the update Pete

I'm not that far advanced on my Simplex rebuild, I've fallen a bit behind schedule what with holidays and things.

But that grate looks to be just the ticket

Stew
Title: Re: Another Simplex Refurbishment
Post by: steamer on July 13, 2013, 02:13:39 PM
Nicely done Pete!

The grates on my boat are just about identical...but of course...I can't dump out the bottom! :lolb:

Clinkers,

Clinkers are a fact of life, and are very dependent on the ash content of the coal you're using.   On "Sabino", which has  8' x 8' grates, a clinker is about the size of a flattened basket ball.....and passes as much air through a grate!...To deal with it, we push the fire back, uncovering the grates, and then rake it forward bit by bit and pull out the clinkers onto the deck and shovel them into the ash pit.   After which we pour on more coal.

OK so what does this have to do with your loco?

One thing you'll notice when doing this is the 'feel' of a clinker when the rake hits it.   It feels like bread dough.   and it sticks together...so a slicing bar can be used to peel it off the grate...and the rake can drag it out...though I rarely used the slicing bar....the rake worked pretty well and it's not real pleasant to do this so you do it as fast as you can.

I suspect, though I can't speak to it on this scale, but I suspect you could feel a clinker with your poker, and a quick scrape....it's out.

Dave
Title: Re: Another Simplex Refurbishment
Post by: doubletop on July 14, 2013, 08:25:01 AM
Thanks guys I thought I'd share it as this is a problem with the original Simplex.

Dave - the trouble with managing the fire on one of these locos is the fire door is only just over one inch in diameter so there's not a lot of room to do clinker management,



I'm not that far advanced on my Simplex rebuild, I've fallen a bit behind schedule what with holidays and things.


Stew - I guess your club chairman is sad to have to let you go? You did say you'd asked him to ban you if you didn't get your loco running by the summer and you're well into summer now. OK I accept you've had a bit more to do than you'd expected. That, and my latest ME turned up yesterday with another of your creations gracing the front page.

regards to you both

Pete
Title: Re: Another Simplex Refurbishment
Post by: steamer on July 14, 2013, 01:54:05 PM


Dave - the trouble with managing the fire on one of these locos is the fire door is only just over one inch in diameter so there's not a lot of room to do clinker management,





YUP....that was my point...can you FEEEEL it ...with the poker....I think I'd have to stand on my head to see it! :ROFL:

Dave





Title: Re: Another Simplex Refurbishment
Post by: doubletop on July 15, 2013, 07:11:03 AM
Dave

When I'm running again I'll have to have a ferret about and see if I can find any clinkers.

Pete

(I sense that this could now regress into schoolboy jokes...............)
Title: Re: Another Simplex Refurbishment
Post by: steamer on July 15, 2013, 11:50:14 AM
Ohhhh No......No No....

Ain't goin there!

Dave
Title: Re: Another Simplex Refurbishment
Post by: doubletop on August 12, 2013, 11:23:30 AM
When I was ordering the grate from Blackgates I saw they also stocked the Southworth vertical steam pumps. One of these has been on my project bucket list for a while. I went for the 3" because the 6" would be too large for a loco this size. If it was too small it could always go on the Rob Roy. Anyway for 28quid it wasn't going to break the bank.

Ordered on the  8 July, delivered to me in NZ in about a week later and finished a week ago. As Stew had done a good write up over here
http://madmodder.net/index.php/topic,4763.0.html (http://madmodder.net/index.php/topic,4763.0.html)  there wasn't much point in doing another one. But I have added a few points to Stews thread to help others.

(http://i.imgur.com/j1CnjaG.jpg)

and running, 20psi in and 60-70 psi out (and with leaks). The 1/2" steam piston and 1/4" water pump ram gives a theoretical gain of 4

http://www.youtube.com/watch?v=66TODmf6JJU

I had identified some drawing errors and found Bob Potter, who is now the proprietor of Southworth, is a member of this forum so I've been in touch with him. The 3" pump does seem a tad small for a 5" gauge loco  so I was toying with the idea of making a scaled down version of the 6" pump.

To cut a long story short; my intention to take the Simplex out to the track this weekend to try out the new grate was thwarted by heavy rain. So what else do you do on a wet Sunday? Install the pump....

(http://i.imgur.com/CBTlsN8.jpg)

I had it running on air this evening with water in the tanks it was capably filling the sight glass. With the boiler full and the regulator shut and the pump ticking over I got it to a hydraulic pressure of 30psi. It would have done more if I'd let it.

With a single acting pump and about a 2cc displacement it not going to get me out of trouble. But with the hand pump, axle pump and injector it's only there for show topping up when stationary for long periods.

If you want to try your hand a clock making this pump has enough little parts to make it an interesting build. I thoroughly enjoyed doing it.

(BTW all that 'rust' on the saddle and smokebox is copperease grease from when I had the boiler out)

Pete






Title: Re: Another Simplex Refurbishment
Post by: NickG on August 12, 2013, 06:46:56 PM
That looks good pete and sounds promising. I've always liked the idea of these but have never seen one in action at least not in our club.
Title: Re: Another Simplex Refurbishment
Post by: doubletop on August 13, 2013, 11:06:52 AM
Nick

Hopefully I'll get a chance to try it this weekend and get a video. I've seen locos with Westinghouse pumps and the gentle pumping action and the hiss of steam every stroke is quite mesmerising. Hopefully this Weir pump will be similar. Apparently Weir pumps do have a tendency to short stroke. This one only seems to do it if too much oil is applied through the airline. I think it must affect the way the shuttle functions. Lets hope it will be a bit different on steam and the displacement lubricator.

I had another play tonight doing a hydraulic test and with 30psi air pressure into the pump and the pump ticking over I had it holding the boiler at 90psi water pressure with one of the safety's just weeping. The principle reason for the test was to take the opportunity to check for any minor leaks in the pipework disturbed  after having the boiler out. Having the pump running like that saves constantly tending the hand pump to maintain the pressure when doing the test as even a pretty small leak will dump the pressure pretty quickly.

Pete
Title: Re: Another Simplex Refurbishment
Post by: NickG on August 13, 2013, 02:10:32 PM
I can imagine them being quite nice to watch.  :ThumbsUp:

Sounds like it's performing well then.
Title: Re: Another Simplex Refurbishment
Post by: doubletop on August 25, 2013, 11:43:31 AM
Well the lack of an update means that the track test last week wasn't that sucessfull. the thing would just stop for no reason and vent straight to the exhaust. I spent a bit of time this week tracking down the problem to the valve lifting and remedying the problem. I've posted the details on Stews old thread to keep the information together for others.

http://madmodder.net/index.php/topic,4763.msg97752.html#msg97752

(http://i.imgur.com/pDYLzDD.jpg)

Now it behaves itself

http://www.youtube.com/watch?v=Rp00MhFsAsM

I had it at the track today and it was ticking away happily to itself all afternoon and was adequately pumping water when I upped the pace

regards

Pete
Title: Re: Another Simplex Refurbishment
Post by: Mr Moo on August 24, 2018, 08:18:23 PM
Just bookmarking this so I can find it again !

Very nice work :)