Model Engine Maker

Engines => Your Own Design => Topic started by: steam guy willy on February 19, 2015, 01:48:12 PM

Title: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 19, 2015, 01:48:12 PM
I Have started this new engine of the Woolf Compound A frame engine. It is tucked away in the corner of Essex near Maldon It was built circa 1820 ? and was installed in the mill about 1845. The mill burnt down in 1875 and was never rebuilt  due to the corn laws &&&&. It has remained intact ever since and is original and unaltered since then. Most of the nuts and bolts are square headed and there is a lot of Ovolo mouldings all over it. It is currently being restored and i have permission to make a model of it.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on February 19, 2015, 01:49:23 PM
Cool!   Pictures please!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 19, 2015, 01:58:41 PM
some photos of the engine and the maquette to sort out the inner workings of the cylinder block one in wood and the other in perspex
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 19, 2015, 02:04:16 PM
Photos of the perspex engine maquette this is the HP cylinder..........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: sco on February 19, 2015, 02:56:11 PM
Interesting project Willy - thanks for sharing!

Simon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Johnb on February 19, 2015, 06:48:52 PM
Thanks for those pictures. A very interesting project. Interesting to see the cylinder covers being held down by bolts, albeit square headed ones, rather than studs. I thought studs were universal for this application. You live and you learn!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Jasonb on February 19, 2015, 06:57:40 PM
So are you making this one all from clear material? Or just getting a feel for the basic layout of the major components before cutting metal

Quite similar to the slightly later one at Preston's though an A frame rather than single column
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Roger B on February 19, 2015, 06:59:10 PM
I suspect that studs did not appear until "mass production" started. Why cut two sets of threads instead of one  :headscratch: (especially when you are doing it by hand  ::) )
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: philjoe5 on February 19, 2015, 07:01:35 PM
This is a rather unique project.  I see JasonB got ahead of me with the question about making it in clear material or is that a bit of pattern making?

I appreciate the work in your drawings too :ThumbsUp:

Cheers,
Phil
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 19, 2015, 11:11:11 PM
Thanks for all the interest this has generated, The construction of the perspex "maquette" is to try and sort out what is happening in the inside of the compound engine. On most compound and triple expansion engines the cylinders are connected by outside pipes. on this engine everything is concealed in the massive cast engine block and one can only sumize  what is happening inside from external protuberances etc etc etc . They are slowly taking the engine apart and a endoscope would be handy. Bothe cylinders are steam jacketed and there is little evidence so far of drain cocks for the cylinders !. I have been trying to find out about these engines but there is very little so far, also there is a dearth of this type of engine in drawings and castings available. Here are more photos of the how i think the insides work. This n
maquete is not quite to scale as i have to take more measurements
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 20, 2015, 12:34:58 AM
Thanks Jason for the pics , there seems to be drain pipes on the Preston engine you posted. The down bipie is fitted to the jacket here this is to provide steam to the valve and also to make room for the cylinder down pipe to get the steam to the other end of the cylinder. Quite a bald looking cyl block on the Beeleigh engine !! also there is sign no of wooden cladding
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on February 20, 2015, 01:11:16 AM
I agree with what the others have said Willy; very interesting project. I too was wondering initially if you were making patterns or what your were up to.

I will be following along to see what you learn and where this project goes.

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: sbwhart on February 20, 2015, 06:51:18 AM
Real interesting project of a very nice looking engine I love the architecture on the cast iron column, I'll be following along with great interest, keep the posts coming.

Stew
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 20, 2015, 12:27:16 PM
the maquette is coming along fine ,The outer down pipe is glued on. this protrusion has two functions one is to allows steam from the jacket to enter the main steam and govenor valve and to allow clearance for the  down pipe of the cylinder from the ports. also i have the capston fitting for the tailstock so i can drill those 1" holes again.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 20, 2015, 04:15:51 PM
More pics of the engine..........The gland bolts on the piston rods are acme type threads and as there is only 1 nut this would work ok !.The govenor is an original Watt type and the beam ends are of the acorn pattern ,This is what attracted me first to this engine as the Bridewell has the same design as well as the Hedley.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Jo on February 20, 2015, 05:14:46 PM
:naughty: Inner and outer straps on the beam ends I fancy making an engine with those myself now I seen them   8).

Jo
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 21, 2015, 12:58:19 AM
i have now sort of completed the HP cyl set up and this will give me an idea how to construct the real one i.e. get the sequences in the correct order etc etc, the LP cyl will be next............. :help: :headscratch:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on February 21, 2015, 09:22:01 AM
The steam jacketed cylinder is interesting Willy, what do you think the purpose of that was? I would have thought that the cavity would fill with condensing water as the steam cools with every exhaust stroke. I know that traction engines had cylinders warmed by boiler steam, but they were sitting on top of the boiler, this is somewhat removed. Hmmm. Hugh.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on February 21, 2015, 10:42:09 AM
Steam jacketing was used to reduce condensation losses.  You control the temperature by throttling the steam in the jacket.

Remember, this is a compound, and an early one at that.    Steam pressures were probably not really high enough to really take advantage of it.

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 21, 2015, 04:27:58 PM
some pic's of the drawings for the Beeleigh engine. You will notice on the cyl head drawing the bolt holes are not equally spaced ,so am i going yo do this on the model so people can say    oh look at his bolt spacing's  "Rubbish" !!.......................
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Beam Engineer on February 21, 2015, 06:34:58 PM
Hi Robert,

My first post and thanks for telling me about this site!

This looks a most interesting subject: Wentworths of Wandsworth built a number of engines to this basic design and two of them still(?) exist also in Wandsworth at what was the Old Ram Brewery.

The first engine ("12 Horses Power") was built in May 1835 (rebuilt to 16hp with a rebore in 1865) and like the Beeliegh engine it had swivels on its beam ends to cater for any misalignment when installed on site - a common problem in the earlier years of engine building as cast iron was rather unpredictable in those days before proper empirical analysis in metallurgy. By the time the second engine was installed at The Ram in 1867 - metal technology and the confidence to machine it with accuracy had both improved - Wentworth's were confident enough to supply the engine with solid cast beam ends with the piston rod and conrod (or should I say Sweep Rod?) pins pushed in to the rigid beam ends.

The swivelling ends were a carry over from the early wooden framed beam engines whose wooden beams would change shape and "move" as carpenters say, with changes in humidity and temperature. James Watt incorporated the swivel end to get around this which was exacerbated by customers having their engines made as cheaply as possible (clients had to find their own carpenters and smiths as Boulton and Watt only supplied the cylinders and valves) often with unseasoned timber as the Napoleonic wars caused wood shortages because it was needed for Royal Navy ships. I'm not sure if Watt actually invented the swivelling beam end; early engines were built by millwrights who'd often got the accumulated knowledge of generations of their family in the trade and it was from these craftsmen that he got the idea of using a centrifugal governor. Watt was far too severe and honest a man to lay claim to anything that wasn't his idea.  Although it's often called a "Watt" Governor, he never laid claim to it and always pointed out the error if it was stated in his presence.

I would love to visit the Beeliegh site at some point and take 10,000 photos for reference. For that matter I'd like to visit Wandsworth again and see if the two engines still exist on their original site, which became expensive yuppie flats a few years ago, with the promise that the engines would remain. When I viewed them in the late 1980s, both were oiled up and ready to go at a moment's notice in case the electric pumps which replaced them broke down again.

I could burble on and on, Boring for England on this subject as beam engines are a passion of mine and I've been working on one of my own design (built to practices and formulae used by contemporary makers) for AGES! Now that I have a hut of my own and am slowly getting my workshop ready, I hope to be able to continue with my engine and finish it within the next 93 years. For any of those of you who are still awake at this point, I'm going to try to attach a happy snap or two of my engine in its current state. I long to get it out of storage and carry on with it!

Regards to all of you,

Mitch
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Beam Engineer on February 21, 2015, 06:36:27 PM
Here's the other photo I tried to post...

My best,

Mitch
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: sco on February 21, 2015, 06:47:51 PM
Welcome to MEM Mitch - please post some more pictures of your engine on a new thread ;-)

Simon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on February 21, 2015, 07:32:27 PM

Steam jacketing was used to reduce condensation losses.  You control the temperature by throttling the steam in the jacket.

Remember, this is a compound, and an early one at that.    Steam pressures were probably not really high enough to really take advantage of it.

Dave

Thanks Dave, I thought that the pressure might have been a little low.

Hi Mitch, lovely engine, interesting story. I look forward to more.

Willy, nice drawings, when they see the quality of your work, I doubt too many will question the the hole spacing.

Hugh.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Beam Engineer on February 21, 2015, 08:46:21 PM
Having seen the quality of Willie's work, I'd think that if anyone spots the hole spacing, they'll assume that it's meant to be like that.

Thanks for the comments about my engine: I've got to dash but I'll see ifIi can start a fresh thread about it, with a bit of background blurb.

Kindest regards to all of you,

Mitch
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 22, 2015, 12:18:32 AM
Having seen the quality of Willie's work, I'd think that if anyone spots the hole spacing, they'll assume that it's meant to be like that.

Thanks for the comments about my engine: I've got to dash but I'll see ifIi can start a fresh thread about it, with a bit of background blurb.

Kindest regards to all of you,

Mitch
Hi Mitch ,i have now read your post in detail and notice your "SWEEP ROD" comment....... I am allways searching for the correct ternimology/terminology to talk about various parts of steam engines as the language used can be misleading, What about a definitve illustrated glossary  of parts, with all the various spellings etc. Linnaes did this for vegetable plants so what about one for steam plants !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steam Haulage on February 22, 2015, 09:50:46 AM
Hi.
Great to see the work by steam guy willy and beam engineer. I especially like the descriptive text that both of you are providing. I have a long-time interest in beam engines but Crofton, for all it's good points provides only one approach to power. I had no idea these engines existed, although I had heard tales about the Ram Brewery.

Please keep up the good work.  :ThumbsUp:
Jerry
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 22, 2015, 03:36:21 PM
A couple of pages from the Rev Dr Lardners book 'The Steam Engine' ......Disparaging remarks about Mr Woolf! and lots of tasty pics plus pages that were never slit open !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 23, 2015, 01:14:22 AM
The LP cylinder is tackled next with the cyl porting down pipe glued on. Hugh the steam jacket was used to keep the cyl steam up to temperature to keep the pressure up ,but there is no jacket cladding so not very efficient on this engine, however this is quite an early engine so everyone was a prototype, so ,I think this is correct. I never studied thermodynamics so am a bit in the dark ,like the jacket !! Mitch could tell us more i am sure............
 


Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steam Haulage on February 23, 2015, 07:48:40 AM
Stem Guy Willie,

Is that the Dr. (Dionysius) Lardner who entered the fracas over Box Tunnel to question Brunel's competence?

Jerry
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 23, 2015, 03:33:12 PM
Stem Guy Willie,

Is that the Dr. (Dionysius) Lardner who entered the fracas over Box Tunnel to question Brunel's competence?

Jerry
Yes it is the same Lardy Dinosaur  himself .......he questioned quite a few people in his time but as he was a Rev then he was still smarting from the churches stance that the sun went round the flat earth !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 24, 2015, 02:21:38 AM
the HP cylinders with its covers and oversize square bolts ! I still haven't decided on the exact scale size yet for this engine. As the flywheel is about 14' 6" and i only have a Myford that may limit the finished dimensions . :-\
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 25, 2015, 01:40:06 AM
continuing the LP cylinder, also i have modified the new Myford tailstock tube part ,To stop drills and reamers etc etc turning in the 2 morse taper part i have drilled through the shaft and inserted an 8mm grub screw in the position of the tang !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 26, 2015, 01:18:49 PM
More to the LP cylinder and I have decided on a scale of 1/18th as my lathe can only turn up to about ten inches for the flywheel.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 27, 2015, 03:14:44 AM
The LP cylinder block is nearing completion. Using the rotabroach speeds up material removal and also provides a pile of short circular stock.And ......................last year i had an accident with my Apple macbook air when it fell into a tub of water!!! needless to stay it stopped working..........so i purchased another one fairly cheaply any way today i tried to see if it had come back to life ....and to my surprise it just fired up like a time capsule and it is working again !!!!! so if it happens to any one else just wait 212 days..........the battery is not working however ..only on mains power....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on February 27, 2015, 04:46:38 AM
This is a very interesting approach Willy, I'm watching when my internet connection permits. Did you get the new tailstock nut? Hugh.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 28, 2015, 09:20:44 PM
The maquette is continued with, however on the LP cylinder side there are three pipes that come down from the steam chest and i don't know why there are 3 of them. The Middle one is foe clearance for the cyl down pipe on the inside, and one of them is to take the exhast to the pump. But what function does the other one have apart from balancing the aesthetic visuals, I won't get a chance for a month to look further, so has anyone any ideas ?? Hugh ,I ave bought a Capstain tail stoke drive and am using that for now and i may have located a serviceable one locally Thanks
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 01, 2015, 02:27:40 AM
The porting is being sorted on the maquette, the holes drilled and filled with FIMO to see them in the perspex.! also some 'cooking' to fill the spaces between the two cylinders. Just checking to see if the resin react's or melts the FIMO as this will form a 'core' to complete the exhast channel twixt the HP cylinder to the LP valve chest, and see how well it adheres to the perspex on its own  it seems to be ok :ThumbsUp: :ThumbsUp:  Also for a bit of light relief a pop up book, A leaf taken from my Modern Power Generators book  (not literately ) This is to show future generations how it was done, as every thing in the future will be solar,wind,tide etc etc etc.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steam Haulage on March 01, 2015, 11:27:34 AM
One question and one comment.

What the heck is FIMO?

If you look at Lardner's commentaries and pitches on any subject you will see that he was a particularly nasty piece of work. Opinionated is one description used, he should have stuck to the subjects he knew something about.

I know one should not speak ill of the dead but he must have cost this Nation a fortune in wasted time.

Jerry :old:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: sco on March 01, 2015, 12:46:57 PM
Fimo is a modelling clay.

Simon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 01, 2015, 01:01:51 PM
One question and one comment.

What the heck is FIMO?

If you look at Lardner's commentaries and pitches on any subject you will see that he was a particularly nasty piece of work. Opinionated is one description used, he should have stuck to the subjects he knew something about.

I know one should not speak ill of the dead but he must have cost this Nation a fortune in wasted time.

Jerry :old:FIMO is a modelling composition used to make novelty items for sale in craft shops etc , it is a much used toy by children etc for making little animals etc, It is first modelled and then put in the oven to harden rock hard. Yes Lardner.................couldn't agree more ! A bit like trethithick patenteing the wheel/crank, that was used in spinning wheels for centuries before he came along !!,        More experiments with resin  it is now 12 hours old and is still very pliable !! more pics.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on March 01, 2015, 07:01:28 PM
Err...what what sort of 'experiment' were you conducting with your namesake confection? Hugh.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 03, 2015, 02:36:18 AM
The perspex model is nearing completion apart from the LP exhaust arrangment. I have used green Fimo for the inlet ports and red for the HP exhaust to the LP steam chest . Also there is extra metal between the two cylinders which will be filled with Resin. However i need to get nice fillets between the two cylinders ,hence the convienently sized miniature (free samples from the local pub)I am going to Cambridge on Wednesday to photograph and measure up the small Hedley steam engine whigh will be undertaken concurrently with the Beeleigh
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 08, 2015, 10:51:42 PM
I am now using 'Resin' to fill the gaps with fillets and to hold the two cylinders together. as i have to rely on gravity this is taking a while as i have to wait 3 days for it to set. I also have to build it up between the two cylinders at the top to encase the red exhaust port to the LP steam chest using plastocine I have been to the Hedley engine in Cambridge and took about 160 photos and am commencing with accurate drawings to build it
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 12, 2015, 01:04:17 AM
The maquette is taking shape and the cross channel for the exhaust transfer is cast around the red Fimo with the resin. The green Fimo denotes the inlet ports and the oange is the LP cylinder exhaust to the condenser.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 13, 2015, 02:26:39 AM
The down pipes are now affixed and the left hand one is the LP cylinder exhaust to the condenser, Also the bass is begun
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on March 14, 2015, 05:08:59 AM

Also the bass is begun

I guess you can't keep a good luthier down. Hugh.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 14, 2015, 06:34:03 PM

Also the bass is begun

I guess you can't keep a good luthier down. Hugh.
Hugh, I ment to say.........the repair to the double bass is begun !!  Also we have managed to stop patchwerk rail demolishing  Trowse railway station !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on March 14, 2015, 08:05:11 PM
Funny how some people will just happen to have a broken double bass hanging around. My acoustic guitar has an issue in the same spot, but not to the same extent. What glue will you use?

Good news about the station, what do you think might become of it now?

Cheers, Hugh.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 16, 2015, 11:14:26 PM
Funny how some people will just happen to have a broken double bass hanging around. My acoustic guitar has an issue in the same spot, but not to the same extent. What glue will you use?

Good news about the station, what do you think might become of it now?

Cheers, Hugh.
Hi Hugh, the bass is now gluing.......the secret is to use very strong clamps with extra wedgey shaped bits of metal to get the clamps central in the correct planes,because instruments are all curves etc etc etc. I use resin W glue for most things now. The station is being left to slowly rot away as far as i can tell. It is not listed but is in a conservation area, so it is still not 100% safe yet.
Willbert.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 20, 2015, 02:33:59 PM
hi,The Beeleigh is now on hold for a bit as i am waiting to go down and make more measurements etc .I have photographed and measured up the Hedley engine in Cambridge and have started with a perspex base to get things in the right place. I will start a new post called The Hedley beam engine.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 20, 2015, 06:21:29 PM
That Hedley is a graceful engine, should make a really nice model. Looking forward to the build!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 28, 2015, 06:23:26 PM
I have revisited the Beeleigh mill engine and taken more photos and drawings. I took down an endoscope but, that will take some getting used to. Should i copy the broken steam chest bolt ?? More of the engine workings is becoming clearer and the two offset down pipe protusions on the Cyl jacket appear to be both used for the LP cyl exhaust system to the condenser. This was possibly made like this to balance up the casting process as well as looking aesthetically pleasing?. I also fell over and hurt my shoulder, and the water bypass pipe on the Moriss burst as we came into Norwich, hence lots of steam !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on May 28, 2015, 06:25:23 PM
Engineering as an art form!.....Sweet! :ThumbsUp:

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 19, 2015, 09:50:40 PM
I am now continuing with this build as the Hedley engine is almost finished...........This engine will be quite challenging as all the victorian cavetto mouldings will have to be reproduced accurately as well as the beam end profiles. i may make an extruding tool to squeeze out lengths of lead solder bar of the correct profile. this will be bent around the curves and glued into position...........I have not decided exactly what scale i will be using yet although 16BA bolts and screws are available!!It will be mostly bar stock construction but will see what happens.......some pics showing the castings a !!nd also the linkage for the Horsepower indicator, except how it works is a mystery
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 23, 2015, 06:50:29 PM
drawings to start on the engine I will start with the base first. this is quite plain and as they engine will be 1/16 scale, it will be about 10"X 3" X .5" small/large......As the flywheel is quite large and there is the condenser and air pump beneath the base it will be built on some sort of plinth brick or stone maybe.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 25, 2015, 09:16:19 PM
I have now purchased a piece of 15mm X150MM black bar for the base and after cutting to length one side is milled to give a square facing edge to use as the datum point for marking out, The base is a massive slab and should be 1/2" thick in 1/16 scale but i shall leave it 15mm for now. there are various lugs that are used to position the A frames and i think they may be cast in as there is a lot of room for the packing and although there are nuts on them there are no other holding down bolts visible to secure the base. The retaining bolts are usually very long, about 4' long to keep the base secure. One way to see if they are cast in is to use a magnet and iron fillings. Also if the a frame does need aligning prior to bolting down the strain on the lugs might shear them off. The base has cutouts for the engine to be handed on the base although the gap for the crankshaft and flywheel cannot be reversed. some pics......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 26, 2015, 12:36:23 AM
The base slab has been angle grounded off, and milled to size ready to be marked out.........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 27, 2015, 01:25:08 AM
I will be making a perspex model of this to see how everything fits together..........this will just be a simple representation so no mouldings etc....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on November 27, 2015, 01:36:51 AM
Willy I will be following alone on another one of your great model engineering projects. I am pulling up a chair for the ride.

 :cheers:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 27, 2015, 01:02:24 PM
Willy I will be following alone on another one of your great model engineering projects. I am pulling up a chair for the ride.

 :cheers:

Don
Thanks for the post, and i hope i don't disappoint anybody......This will be quite a lengthy project i fear....I have not seen many models of this type of engine about and i don't think there have been any kits or plans produced for an engine such as this with the Woolf compound and condenser and pump arrangement. Incedentely here in  norfolk at a place called Lound there are a pair of Easton and Anderson  grasshopper engines that are on my list to make !!They have been taken out of commision with the steam pipes removed.
Willbert.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on November 27, 2015, 09:23:20 PM
I doubt I'll be disappointed, but I will be watching. A compound! Hugh.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 28, 2015, 12:04:21 AM
this is the actual size the engine will be at 1/16 scale............
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on November 28, 2015, 01:20:26 AM
Hi Willy

Good to see this project moving along again; I had to go back and and do a quick refresher to remember where you left off.
It will be enjoyable watching this one come together.

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Johnb on November 28, 2015, 08:41:31 PM
Hi Willy. Great to see this one on the go. I loved your engine at Forncett and seeing the finishing touches coming along since then. This is going to be another interesting build. Thanks for posting.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 30, 2015, 02:19:13 AM
the perspex base is made and the standards are drawn out and glued to 2 pieces of perspex ready to cut out. Doing this this way enables one to see how to tackle the process when using steel for the A frames proper. Also Johnb.....this is a very interesting project for me as well as i am learning so much about how these engines were made and how they work !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 01, 2015, 01:51:59 AM
The "A" frame stations are made and are awaiting the top bearing and side pieces also the governor stretchers need to be drawn up and made.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 02, 2015, 01:50:28 AM
the front A frame is made ,all glued together so is a bit flimsy !!............
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on December 02, 2015, 12:03:19 PM
Once again, your model of a model is is a remarkable way of building a prototype. Is this one somewhat larger than the previous two that you've shown here? Hugh.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 03, 2015, 11:44:55 PM
Once again, your model of a model is is a remarkable way of building a prototype. Is this one somewhat larger than the previous two that you've shown here? Hugh.
Yes, this model will be 14" x 14" x 5" this is to avoid watchmaking with some of the parts ! I cannot seem to post photos at the mo ??
Willy
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 04, 2015, 02:11:21 AM
more pics.....the base needs to be changed slightly as the photo shows and the other a frame is completed
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 08, 2015, 01:40:05 AM
The cylinder base is now made and in position. It is quite quick using perspex ,i have a large quantity collected from skips. One just saws it up on a mini bandsaw and glue it together......The model will be quite large with a few parts under the base......the condenser (posh word for a bit of pipe) and the air pump ,that actually pumps water into the boiler feed water pump. I am still trying to find other models of these Woolf compound engines possibly working under steam ,so ,if anybody has seen any please post them.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 13, 2015, 01:09:21 AM
The underneath of the cyl table is glued on, this is the casting connection for the condenser pipe. I was rather confused as to the exhaust arrangement via the LP cylinder and have surmised that the exhaust passages divide and exits via the two protuberances at the front of the cylinder casting. The cylinder block was cast this way to look aesthetically pleasing as well as to balance the shrinking forces to stop too much distortion when the casting cooled.......i think !!You can see on the HP web where the casting has shrunk !also the steam jacket drain pipe connection.Also i saw this in the Model engineers mag from the BBC and was wondering about submitting an application !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 15, 2015, 01:52:53 AM
The steel base is started with chain drilling sawing and filing, Hopefully i should only have to do this once unlike the Hedley that took 3 attempts !!  This is the advantage of making the perspex one first.Also i found a vid of the Dogdyke engine in the Fens That shows the starting procedure with the separate jet condenser lever that is similar to the Beenleigh   I think......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on December 15, 2015, 04:28:16 PM
looks like a good start! 
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 16, 2015, 01:04:24 AM
the next base cut out is done, The large hole is made to accommodate the hacksaw and after chain drilling the corners are filed square to get the saw into the best position to cut out the piece. the next job is to file it square, quite a long and arduous procedure........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on December 16, 2015, 01:19:07 AM
Willy good to see you making head way. Looks like you have a lot of work cut out for you judging from your start on the base. Still with you mate.......... :ThumbsUp:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 17, 2015, 02:05:46 AM
Willy good to see you making head way. Looks like you have a lot of work cut out for you judging from your start on the base. Still with you mate.......... :ThumbsUp:

Don
Yes i think i am cut out for this sort of activity......my thumb certainly thinks so.!! Another hole filed up and the next one drilled and sawn out.!!

Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on December 17, 2015, 12:08:32 PM
Ouch! How thick is that baseplate? Hugh.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 18, 2015, 02:53:40 AM
The base has its holes now cut out, quite a lot of hard work......
Ouch! How thick is that baseplate? Hugh.
The base is 1/2" plate however it will milled down to .4375 " There will be other local thinning of the top and the circular part will be about .1" thick with some webs.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 19, 2015, 11:33:07 PM
still trying to sort out the measurements. I have made a large full size drawing on my floor to see how accurate the dimensions are and to tweet them slightly to make the parts fit.The full size engine is about 70 miles away so i don't get there very often. Also a photo of the condenser control plate that has ERECTEED spelt with two e's!! It actually says  ERECTED for 12 HORSEPOWER.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 20, 2015, 01:59:58 AM
more 'drawing'
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 21, 2015, 01:05:26 AM
i have now been experimenting with the webs on the A frame cut outs . as this is a bar stock engine i will not be using castings yet so have to simulate the casting features. The round parts are turned and the web thickness and width are turned up before parting off. a central hole is drilled in both parts and then bolted to the main plate in the correct position before soldering on. the parts are then chain drilled and sawn out then filed up. When i do the proper ones i will turn a slight taper to be like the "draft" of a regular casting........Oh and cabbage white caterpillars on the winter solstice !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on December 21, 2015, 09:23:28 AM
Hi Willy,
 They are looking good, still quietly following along.
Don't you just love cabbage white caterpillars..... :rant: :rant:...SWMBO uses derist dust ( think that's how its spelled) seems to slow them up a bit...failing that picking them off the plant & a foot fixes them!! Or chooks a pretty good....but they do a bit of damage in there own right....

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 22, 2015, 01:42:33 AM
The cylinder entablature is made out of brass and all the basic parts are cut out and ready to be assembled. Before that the curved cut out parts will be made and soldered in place first................
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on December 22, 2015, 01:54:09 AM
Clever way to do the 'casting' look - watching along with great interest here too!

 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on December 22, 2015, 01:59:33 AM
Cool Willy, are you planning to soft solder or silver solder?

 8)
Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 22, 2015, 02:54:12 AM
Cool Willy, are you planning to soft solder or silver solder?

 8)
Don
The curved hole shapes will be silver soldered and the final putting together will be soft soldered with the odd rivet. the curved webs need to be drilled and filed to produce the contours, so need to be quite strong, and as there is quite a lot of surface area with the rest of the construction, this will be quite strong enough using soft solder.........i hope......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 23, 2015, 03:41:47 AM
More work on the cylinder table. The three top parts are soft soldered together, after first tinning the parts and then riveting them together. The side plates are tackled next with the web parts cut out and screwed and riveted together. these parts are also soft soldered together and i will screw all the sides plates together with the top plate. the web features are cut out on the band saw and then filed up. this was a trial part but will be put on the back now know how to do it !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 23, 2015, 04:19:07 PM
The side view of the cyl table, note the chipped away casting webs on the right hand side to accommodate the HP cylinder valve rod linkage !! This will be faithfully reproduced on the model.......Perhaps the table pattern was used on single cylinder engines initially.  They could have saved a lot of work and metal if the cylinders were placed on the base.......The A frames could have been shorter, as well as the sweep rod ?. So, The extra metal required to make this engine this large seems quite wasteful considering how expensive all the processes needed to make these engines were, including the pattern making and transport costs etc etc etc
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 26, 2015, 12:39:19 AM
more details of cyl table fabrication and a pic of an elevated early compound engine, It has been suggested that this is to avoid damage by flooding but i don't think so. i have now modified construction by screwing the parts together after tinning and then  sweating the parts together.I have a german made vice that can swivel in all directions to enable parts to be held horizontal when filing, it avoids kneeling on the floor !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 27, 2015, 03:21:43 AM
new work on the cylinder base. As the side piece has the bottom lugs protruding the part is screwed to a piece of SRBP before sawing off the waste.this is to keep the plate level.  Just one more panel to finish now before attracting permanently to the top.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 28, 2015, 10:47:01 PM
the sides are being worked on and all of them have been soldered together. now the spaces have to be filed out. also my modified pliers to hold these small parts when drilling
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 30, 2015, 02:14:24 AM
the cylinder progresses. the sides will be screwed to the top . when tapping the holes into the top a hole is drilled adjacent to it to prevent tap breakage, it will also lighten the engine by small increments. The screws holding the sides in place will be countersunk and the final parts of the moulding  glued on top of them.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on December 30, 2015, 02:28:44 AM
I've been watching...and looking forward to more.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 31, 2015, 12:52:27 AM
Have now started on the A frames, after a year of looking studying drawing and measuring........I have used some up cycled brass of the correct gauge and have sawn them out leaving the lugs to attach to the side pieces for soldering. I now have to prepare all the webbed parts for the cut outs about 20 of them for the front and back , so ,lots of work on the lathe and bench
I've been watching...and looking forward to more.
Hi Carl, there is lots more still to come, about a years worth possibly!! However it is mostly finished in my brain !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on December 31, 2015, 12:56:27 AM
Willy your making some very interestingf headway. Still with you mate and enjoying it.

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on December 31, 2015, 01:07:33 AM
Nice progress, I think getting it finished in your brain is about 90% of the job.  :lolb:

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 01, 2016, 02:26:46 AM
The side cut outs are prepared. The parts are marked out and sawn ,then filed to fit accurately then the other 3 are made from them. the circular parts are next.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 01, 2016, 11:10:36 PM
The circular parts are now made......there are two of them each size so two blanks were cut out square and soft soldered to a thin steel backing plate. This was attached to the faceplate and a central hole drilled to align the part on the A frame and then turned to size, desoldered and temp attached. The top cut out has also been made and bolted in place. The triangular parts now need to be adjusted to follow the contours of the central cavities.the other pair of circular parts will be made the same way. the parts are also held in a thin piece vice from a car boot sale to clean off the verdigris prior to soldering.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 03, 2016, 03:21:27 AM
more work done, the bottom circular openings are turned up and i have turned an adjacent slot this time to mark out how much to remove when all the holes are cut out. as these are made in pairs i can only do this with the outermost part. I keep changing how i do things at the moment!!. the bottom stretcher is made with the cut outs for the tabs and one of the side pieces is started. the bottom part of the side piece is perpendicular for about 3/8" and to make this easier to bend at this quite tight angle i have filed away some of the inside with a small round file. So, only the other side and the top part that holds the main beam bearings now..
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on January 03, 2016, 11:45:50 AM
Watching, as always, love the intriguing shots of hopelessly rusted bits of of old machinery, and seeing how you make them. Will you replicate the rust? Happy new year, Hugh.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 04, 2016, 02:25:20 AM
I have made the bottom bolting to the base part that runs the full width of the A frames. Also the side parts are attached to the sides using the tabs to align them at the correct angle etc, also some views of the vice that swivels in all directions. this is the first one i have that really works and is really stable in use. The bottom of the A frames have been partly cut away to make it easier to remove once everything is soldered together.
Watching, as always, love the intriguing shots of hopelessly rusted bits of of old machinery, and seeing how you make them. Will you replicate the rust? Happy new year, Hugh.
Hi Hugh, "hopelessly Rusty" !! I think the restoration team call it "Patina" !! It has been open to the weather though since 1875 !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 05, 2016, 02:36:17 AM
The top part of the A frames are made, these are milled in one piece together and then sawn apart later, this will ensure that they are the same.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 06, 2016, 01:36:40 AM
The top part is now remade as the first one is about 1/16th  too small and won't quite fit properly. The underneath is also milled out, The top part has a slot cut in it to receive the tabs left on the side members. There is more fitting to be done to get more of a fit to solder.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 06, 2016, 11:41:03 PM
I have now attacher the blanks for the side apertures, first i drilled the retaining holes fixed them with screws and then adjusted the shapes to fit the round parts more accurately, then put on a slight taper. The A frame is now almost solder ready, I shall tin the parts first and may make a suitable jig to hold the parts firmly in place although the lugs seem to be doing a good job.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 07, 2016, 11:28:14 PM
I have been making the stand/base/ hotwell/coldwell/Flywheel aperture today This is to contain the huge Flywheel and the water to operate the condenser and air/water pump. This is going to be quite a large and heavy engine when finished. I have also been investigating the manufacture of the name plate for the condenser control lever decal, if made to 1/16 scale the large letters will be  .6 mm high about the limit of the engravers capabilities !!,still it has to be done to complete the engine. Also where are all the previously made models of this type of engine. I have looked on the web for them but to no avail. If anyone knows of any models like this ,please let me know.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 10, 2016, 01:22:48 AM
I have now made a jig to solder the a frames together, it may look a bit over engineered but it will work and this is what we do ! i will have to remove the paint off the back of the main brass bit first though.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: b.lindsey on January 10, 2016, 01:52:51 AM
All I can say is you must have the patience of Job!!  But then again, such beautiful renditions of these old engines doesn't' come easy. Its a pleasure to see how you do it all and the amazing results. I haven't commented a lot but are still watching faithfully.

Bill
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 10, 2016, 02:11:04 AM
All I can say is you must have the patience of Job!!  But then again, such beautiful renditions of these old engines doesn't' come easy. Its a pleasure to see how you do it all and the amazing results. I haven't commented a lot but are still watching faithfully.

Bill
Hi, Bill, Having decided to make a model of this engine i have to actually do it !!, I knew it would be a challenge but did not realise exactly how it would pan out. I am just as amazed and surprised at what i am achieving as everybody else !!. We are all doing really good things and i feel really lucky to have the opportunity to see this project through and to share it with other like minded people.  :) :ThumbsUp:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on January 10, 2016, 02:15:33 AM
Hi Willy, are you going to soft solder these parts? Quiet a setup you made there.

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on January 10, 2016, 02:19:39 AM
I assume the rubber bands will get swapped for twisted wire before heat is applied?

Clever setup.  Would make a great "what is it" photo without the frame inside it. Would look like a mini iron maiden or something.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 10, 2016, 02:28:59 AM
Yes, Don, they will all be soft soldered as the trial set worked ok.I will have to tin all the pieces first though and try to not lose any bits or get them in the wrong places. there is no load on most of the finished A frames and most of the detail is cosmetic. I am really looking forward to getting this all cut out to see how it looks actually !!. The elastic bands were just used to hold the parts together while adjusting the retaining screws.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 10, 2016, 06:41:07 PM
I assume the rubber bands will get swapped for twisted wire before heat is applied?

Clever setup.  Would make a great "what is it" photo without the frame inside it. Would look like a mini iron maiden or something.
tenuous links,  A frame  Iron maiden ,A team, Face plate. etc etc etc  add more at will !!!!!!!! I wonder how long it will be before that smile disappears !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on January 10, 2016, 07:22:03 PM
 :lolb:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on January 10, 2016, 07:54:10 PM
 :o

 :ROFL:

Perfect!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on January 10, 2016, 09:28:55 PM
And thus always to Ken dolls.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: joe d on January 10, 2016, 09:29:39 PM
Well done, that man! 

And the model is looking good too!

Cheers, Joe
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 12, 2016, 02:31:08 AM
The A frame is now soldered all together after first tining the main part. the other parts are screwed on after smearing with flux. The Iron maiden behaved herself admirably and all went as planned !! All the orifices  now have to be cut out and also the other side made.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: fumopuc on January 12, 2016, 05:21:09 AM
Hi Willy it is impressive. I like your fabrication work.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Johnb on January 12, 2016, 06:13:09 PM
Good to see it all coming together. Smashing job.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on January 12, 2016, 06:33:12 PM
I foresee a lot of drilling, cutting and filing ahead for you.

keep up the good work  :ThumbsUp:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 12, 2016, 08:36:06 PM
I foresee a lot of drilling, cutting and filing ahead for you.

keep up the good work  :ThumbsUp:
The Norwich S.M.E are having the annual auction event this wednesday Tomorrow ,If you want to come and meet the people give me a ring  07796926784, or contact on this site .It is at 7.30 at Angel road Primary school. I will be going with lots of odd items to sell.
Willy.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on January 12, 2016, 08:49:26 PM
Wish I could stop by - but I haven't been able to get the car going fast enough to jump the Atlantic yet... Need more steam pressure!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on January 12, 2016, 09:31:59 PM
unfortunately I'm busy with family tomorrow otherwise id have shown my face. next time maby
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 12, 2016, 11:11:36 PM
unfortunately I'm busy with family tomorrow otherwise id have shown my face. next time maby
the next meeting is the 2nd wednesday in the month, in February, this will be a show and tell evening and i shall be going with some of my models.
Willy
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 12, 2016, 11:16:49 PM
Wish I could stop by - but I haven't been able to get the car going fast enough to jump the Atlantic yet... Need more steam pressure!
If they had let Tesla have a free reign it might be a reality by now !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on January 12, 2016, 11:28:00 PM
The solder job looks like you won Willy......... Nice work mate and this will differently be a beauty.

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 13, 2016, 01:49:51 PM
The solder job looks like you won Willy......... Nice work mate and this will differently be a beauty.

Don
Yes ,that seems to have worked out ok ,and all the bits stayed in place after the drilling and filing ,all that remains now is to replicate it exactly !! :ThumbsUp:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: cwelkie on January 13, 2016, 03:35:39 PM
Very nice progress Willy - I really like that you show the rest of us what is possible in the way of fabricating such pieces.  There is no reason to hold off building something just because castings aren't available ...
Charlie
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on January 13, 2016, 03:45:15 PM
that looks fantastic! you'd never know it was made out of so many separate pieces.

don't think I would ever have contemplated making this way, id have been trying to carve it out on the mill and cursing that I didn't have cnc capabilities, or a rotary table, or thick enough stock, or many many other things.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on January 13, 2016, 03:57:33 PM
That's beautiful, Willie!! Looks like the original. But then, that was the idea wasn't it!!

 :cheers:

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 13, 2016, 04:49:24 PM
Very nice progress Willy - I really like that you show the rest of us what is possible in the way of fabricating such pieces.  There is no reason to hold off building something just because castings aren't available ...
Charlie

Thanks for all the comments, I have made it using metal as per wood as per patterns so it is quite straight forward really, also having made one the next one could be made via a lost wax casting and although you would get shrinkage you could get away with it by having photos  that pretend it is the perspective that makes it look a bit smaller !!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 13, 2016, 04:53:04 PM
that looks fantastic! you'd never know it was made out of so many separate pieces.

don't think I would ever have contemplated making this way, id have been trying to carve it out on the mill and cursing that I didn't have cnc capabilities, or a rotary table, or thick enough stock, or many many other things.
Being soft soldered it will stand up to a certain amount of rough handling, However, i won't be using superheated steam ,as bits might fall off !!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on January 13, 2016, 10:58:33 PM
Beautiful results Willy and well done mate................ :ThumbsUp:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on January 13, 2016, 11:29:55 PM
Nice! This is going into my reference notebook.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 16, 2016, 11:42:09 PM
Back to work after the MEX and a bout of back pain......A few pics of the orifice web parts for the next A frame, and a new drill from Exhibition......it has two switch positions..one for ON, and the other for ON when you operate the down feed . I think the idea is that when the drill catches on exit,you let go and the drill stops to avoid the drillee from continuing to rotate casing a bent drill and mashed fingers............except of course we always clamp the Drillee (the part being drilled). Also a set of small broaches from RDG. 85 pounds. I have also made the crank bearings on the Perspex model. 
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Johnb on January 17, 2016, 08:43:16 PM
Great progress Willy. Is that formica you're drilling into?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 18, 2016, 02:57:51 PM
Great progress Willy. Is that formica you're drilling into?
Hi, J, this is a high density type of building material that is used in public loos as partitions between cubicles. It is about 5/8" thick and is very heavy and quite stable, obtainable from your local building site skip ,free of charge. Here in norridge  i have a friendly site manager that keeps me informed of local sites and what is being discarded !! I have just noticed that the Cock of the North, locomotive had a water tube boiler,,,,,,well it would have ,of course , Wouldn't it !!!!!!!!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 19, 2016, 03:12:33 AM
The other A frame is now soldered together so more work still to be done!! This side is slightly different with the shapes of the triangular holes and the parts have been drilled in the corners with the correct size drill so the filing out should be easier and more exact. The first one will be at the back so it won't be so noticeable. The iron maiden is now hanging up awaiting any other models that may be made!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on January 19, 2016, 03:18:49 AM
That is looking terrific!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on January 19, 2016, 03:24:33 AM
Top notch work Willy and are you planning to paint this brass or leave the brass look.........

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 19, 2016, 03:54:57 AM
Top notch work Willy and are you planning to paint this brass or leave the brass look.........

Don
Hi Don, it will be painted actually to hide the soft solder and the filler!!  I was looking at your photos and see that a lot of your engines are left polished brass, however i don't have the skills to make every thing fit to such a high standards as yours, and as my mum told me  'a coat of paint can hide a multitude of sins' !!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 20, 2016, 01:42:52 AM
The A frames are almost complete, just the tops need tidying up........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on January 20, 2016, 03:03:24 AM
Wow, that's lookin' soooo good! That technique is really somethin'. :praise2:

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 20, 2016, 07:24:21 PM
I have now made the condenser (bit of pipe) jet control box.....The top writing is all there however you may need a magnifying glass to see it. It was made in the local engraving shop and the chap said you won't be able to read it,however the chap on the market fish stall managed !!!It was quite expensive .....12 cups of posh coffee.!! I always price things in cups of coffee as it makes them cheaper.......... This is of course part of the model so it has to be there!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on January 20, 2016, 07:30:45 PM
Nice detail!  They even included the misspelling - great historical touch!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 22, 2016, 02:22:19 AM
The A frame top parts are now attached ,they were soldered in place using a spacer the correct width and with the standards bolted in place and the weight of the base holding everything square. Also the square stub for the condenser lever will be an old 3/32nd reamer end as it has the correct shape, You can also see some of the lettering , 12 HORSEPOWER and a smaller OPEN.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on January 22, 2016, 02:40:51 AM
.....12 cups of posh coffee.!! I always price things in cups of coffee as it makes them cheaper......

 :lolb: That's great.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 25, 2016, 12:56:39 AM
The condenser lever is made and a few spanners from a charity shop....Daimler Austin BSA and of course we all know what went on in Garretts,Leiston !   I will be going to Beeleigh Mill on Tuesday to do more measuring and photo's so the work will continue apace.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on January 25, 2016, 08:22:33 AM

and of course we all know what went on in Garretts,Leiston !

A terrible, dark tale?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 25, 2016, 09:35:13 AM

and of course we all know what went on in Garretts,Leiston !

A terrible, dark tale?
Actually No, They made Traction Engines  actually........The Long Shop is still there and i used to visit in the 70's when i was a school teacher at the famous Summerhill School started by A.S.Neill................
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on January 25, 2016, 09:47:08 AM
Actually, I thought it was traction engines. I've a photo of one taken at the old river port of Echuca on the NSW/Victorian border. It is a very impressive machine, the largest I've ever seen.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 30, 2016, 12:52:30 AM
I went to Beenleigh mill again and took more photos and measurements. The next part to make is the top frame stretcher. I took an imprint of it on a large sheet of paper and after drawing it out i reduced it to size to use as a template the actuall size for the model.....I now have to work out exactly how to do it !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 30, 2016, 11:30:14 PM
the top stretcher is now under construction  the reduced photocopy has been glued to a piece of brass. this is then drilled through with the other parts of brass to retain the correct positions when soldering together. the top and bottom parts are then bolted together and sawn out on the mini bandsaw. they are then filed up together with a draught and reattached to see how they will fit. the centre round bit will be turned up next and the whole lot will be medium soldered together...........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on January 30, 2016, 11:53:50 PM
Looking good Willy and I do enjoy you fabrication work, very intuitive........ :ThumbsUp:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on January 31, 2016, 12:21:05 AM
Thats quite a complex part, nice fabrication!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 31, 2016, 03:45:28 AM
Thanks for the comments and the part is almost finished, I just need to attach the flanges to the arms and legs and narrow them a bit more as well. When it came to it, it actually went together quite easily. The small bandsaw is a real boon though as it takes a lot of the work out of the construction ,it also acts as a very course filing machine as well so here are the pics>>>>>>>>
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 31, 2016, 02:18:09 PM
More on the top part, one of the legs did not take the solder so a quick repair was accomplished using the vice as a heat sink so the don't all fall off !! Also the drawing and reaming the centre hole to give an accurate orifice with a bit of "casting" draft when used from each side...........And a close up of the part......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on January 31, 2016, 05:08:11 PM
More amazing work Willy!  :ThumbsUp:

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on January 31, 2016, 08:20:29 PM
That's a very complex part to make, and a very good way of making it. Hugh.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 02, 2016, 03:00:39 AM
That's a very complex part to make, and a very good way of making it. Hugh.
Thanks Hugh,  There will be much more complexity to do however......especially on the beam ! The top stretcher is now fitted,,,,,,about 2 hours worth of Thou-filing to get the parts to fit exactly...I have to solder it now to the flanges but i don't want the solder to penetrate through to the frame as the part has to be removable......I could use a micro flame torch,but have never used one before ,or even JB weld,also never used that before.......we shall have to see what happens  when it comes to it
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 03, 2016, 02:44:20 AM
the top stretcher is now finished with the flanges in place. I did buy a mini micro gas torch and soldered the part in place on the standards after tinning all the parts. some of the solder did run into the slots on the arms but were removed with a wood chisel. also the legs/arms were made longer and then sawn and filed down, hence the bit sawn off in the photos. The next part will be the bottom stretcher that supports the governor. this will be constructed in the same way as the rest of the A.frames as this process seems to work ok. Also it is the show and tell at the Norwich &DSME at the Angel Rd Junior school on Angel Road.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on February 03, 2016, 03:04:00 AM
Very intricate work.
Neat project!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 03, 2016, 03:22:57 AM
Excellent as always!   :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Johnb on February 03, 2016, 10:33:51 PM
Very fine!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on February 03, 2016, 11:40:59 PM
Willy I can only imagine how much work you put into this part. Outstanding work mate.......... :praise2:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 04, 2016, 03:04:23 AM
Willy I can only imagine how much work you put into this part. Outstanding work mate.......... :praise2:

Don
Thanks for that, I knew it would be a labour of love and it is fortunate that i have as many tools and materials that`have accumulated over the years......A lot of my files have been ground down to suit the job in hand........I also have a large pile of brass offcuts, many of them in soldered together pairs.....I do like the challenge ,and although i think some fabrications will be difficult as soon as i get in the WKSP everything happens as if by magic !!Also there is a lot of really good work going on in this forum that looks quite difficult and a lot of skilful people .......so ,back to the bench !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 05, 2016, 09:28:04 PM
Making the bottom stretcher governor support bracket. A large drawing to scale is first made then reduced on the photocopier to correct scale size. these are then glued to the brass plates and the proving plate to check for size. the top brass plate is then drilled and the holes drilled through to the centre plate to keep them aligned when soldering. The top plate is then sawn out, this is a quick operation on the mini bandsaw, filed to size and checked by attaching to centre plate to check the symmetry.This streatcher has right angled flanges, but these will be be soldered on. the top part of the flange will be attached to the A frame with bolts. The stretcher will be offered up to it, and the bottom part of the flange then bolted in place afterwards.........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on February 05, 2016, 10:29:20 PM
I'm really enjoying how you're taking the real thing and modeling it.
Fascinating.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on February 06, 2016, 01:56:48 AM
I'm really enjoying how you're taking the real thing and modeling it.
Fascinating.

Yup Me too!

Nice Progress Willy.

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 06, 2016, 02:40:58 AM
The stretcher is getting there ,now i have got the hang of this modus operandi......The parts are tinned and soldered together. I removed some of the metal to make it quicker to heat and solder. the test piece is then used to fit the stretcher as accurately as possible as the A frames taper in both planes.The part left on at the back is to support the governor drive fully and bevel gear.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ths on February 06, 2016, 07:23:53 PM
Any more of those to do? You're getting very good at it!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 06, 2016, 08:17:29 PM
I think you are ready to go into full production mode - can we have 1000 by Thursday next?! 

Looking terrific! A very complex set of shapes, coming out great.   :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 07, 2016, 12:35:52 AM
Any more of those to do? You're getting very good at it!
Only the beam that is quite similar but much more intricate with cavetto mouldings etc etc.
I think you are ready to go into full production mode - can we have 1000 by Thursday next?! 

Looking terrific! A very complex set of shapes, coming out great.   :popcorn:
Do you want them plain polished ,painted or just undercoat ?? !!! the  "Flange parts are made, I marked out the position of the stretcher and then drilled the tapped holes from the outside. Then i offered up the right angle brass to the stretcher and spotted through from the outside, i used the angle brass as it was easier to hold. that The reduced governor drawing was tried in place and it seems to fit ok. I will be assembling the Hedley next for the show and tell on wednesday, so will be busy with that.................
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on February 07, 2016, 02:17:47 AM
Awesome Willy, this is going to be a beauty for sure. I...........like.............. :Love:


 :popcorn:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on February 07, 2016, 04:17:18 PM
Impressive!

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 09, 2016, 01:31:43 AM
Thanks Dave and Don still lots to do yet so i hope i can keep it up !! Meanwhile the Hedley is now back together but not quite to exhibition standard yet !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on February 09, 2016, 01:56:55 AM
That's gorgeous Willy.............. :praise2:


Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 09, 2016, 02:54:20 AM
WOW!

 :AllHailTheKing:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 10, 2016, 01:46:40 PM
Thanks Don and Crueby,  it was quite fun making this and is one more engine in my 'stable' now to get back to the Beeleigh engine with more drawings to do.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 18, 2016, 07:26:50 PM
I have been a bit ill and under the weather the past few days with asthma so have not done much work. I am drawing out the governor details but the gears will be a bit tricky.......is there a way of cutting bevel gears with a Tap or will i have to invent something ? also details of a running contemporary Woolf Compound at The Ram Brewery  London...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 18, 2016, 08:30:28 PM
Sure wish there was still machinery like that around here!

Given your filing and grinding skills, sure you could file the profile of a gear cutter on a piece of tool steel. Do you have a fly cutte and a rotary table or index head? Thats how I cut gears for my first couple clocks.

Hope you are feeling better soon, and back to playing in your shop!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: sco on February 18, 2016, 08:56:19 PM
Hope you get well soon SGW!

Simon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 19, 2016, 02:34:00 AM
The pedestal support bracket for the governor. the square headed bolts are filed up from hex headed bolts and the are just bored into the pedestal rather than the A frame as it is almost impossible to drill and tap this unless you have 1/16 size drills and taps . Am feeling a bit better now after the pills and potions and things.

Sure wish there was still machinery like that around here!

there might have been if j p morgan had shares in steam !!!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 19, 2016, 02:53:58 AM
Model Engineers Show & Tell Evening 2016    This is the video of my bit of the Norwich society's show and tell meeting ........Please don't tell the caretaker though about 4 mins into it !!!!
Sure wish there was still machinery like that around here!

Given your filing and grinding skills, sure you could file the profile of a gear cutter on a piece of tool steel. Do you have a fly cutte and a rotary table or index head? Thats how I cut gears for my first clocks

Thanks for that i have never cut gears before but being an Autodidact it will be a new skill in my oeuvre There are 35 teeth on these gears and they are about 13mm outside diameter so we will see what eventualizes as they say across the pond
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 19, 2016, 03:31:25 AM
Those look like a very simple gear tooth shape, like the ones on a clock. Should be possible to make a single tooth fly cutter for that shape with the edge of a grinding wheel. Or even circular saw cut the gaps with the rotary table for spacing, and round the tips with your trusty file.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 21, 2016, 02:25:37 AM
[quote author=crueby
Those look like a very simple gear tooth shape, like the ones on a clock. Should be possible to make a single tooth fly cutter for that shape with the edge of a grinding wheel. Or even circular saw cut the gaps with the rotary table for spacing, and round the tips with your trusty file.

Hi Crueby, I have thought about your advice and have tried to do this using a dremnel tool in the lathe with the top slide set over 45 degrees  The PCD is at 45 degrees but i think the tooth cutting angle is slightly different with a quite complex tool profile. However the beeleigh gears are quite crude so there is more latitude in the tool shape. The part i have made is just a trial piece so i need to get the correct centre height and a proper cutting tool profile. here are more drawings of the gears and the pedestals
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on February 21, 2016, 04:24:23 PM
Looks like parallel depth bevel gears Willy. I don't think it's anything your filing skills can't manage to fabricate. The sample piece is not bad......

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 22, 2016, 01:31:45 AM




Looks like parallel depth bevel gears Willy. I don't think it's anything your filing skills can't manage to fabricate. The sample piece is not bad......

Don

Hi Don i have had a 2nd go at the gear using the dremel .I ground down a small centre drill to width and removed the point. I moved it to centre height and took 30 cuts,Although it should be 32 as per original. and this is the result...... it will be cut in steel though and it will be interesting to see how they mesh . There is an english penny to get an idea of the size the blanks are about 1/2 " So thanks for the advice and stuff  :cheers:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 22, 2016, 02:27:39 AM
Excellent!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 22, 2016, 03:43:25 PM
This gear cutting seems to be a bit easier than i expected, and i find that once in the WKSP just looking at the tools and equipment and bar stock available just makes things fall into place & shape. Also although i make drawings with measurements to half a thou once i get on the lathe i just make swarf with the minimum of measuring.............if it sort of looks right then it possibly is right !!  It may be that 50 years of lathe usage helps and pays off in the end !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on February 22, 2016, 03:46:17 PM
if t looks right, then whos going to argue with a few thou here or there??
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 22, 2016, 04:25:18 PM
If we leave you on a desert island with a stack of metal, a file, and a c clamp, you would come home in a new steam yacht!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 23, 2016, 02:00:15 AM
If we leave you on a desert island with a stack of metal, a file, and a c clamp, you would come home in a new steam yacht!
[/quote

Yes but only if it is summer in blighty !! I do surprise myself sometimes actually...........So the other gear is cut and they do mesh quite well , I machined up a holder in the lathe and set the speed right down and they ran ok !!  A few pics...i did take a video but that will have to wait a bit......So that bit is sort of done. they are made in brass but if they are dull nickel plated or something they could remain brass........Thanks for the comments  etc
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 23, 2016, 11:22:21 PM
this is the video link of the meshing gears also the gears inside the frame awaiting the bearing blocks and the rest of the governor..........more 12BA bolts to make.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 23, 2016, 11:31:57 PM
Nice job on the gears!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on February 23, 2016, 11:33:29 PM
What did I tell you, piece of cake wasn't it? Your the man Willy......... :praise2:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on February 24, 2016, 12:02:10 AM
Nice gear work!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on February 24, 2016, 02:39:45 AM
Very nice Mr. Willy!

I always enjoy your work.

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 24, 2016, 03:09:13 AM
Thanks for all the comments  and this latest bout of work may have been due to the full moon over here in Blighty !!!
The bearing blocks now need to be made and the first one is getting there,  and i need to make some 12BA square headed bolts, I usually just use hex bolts and file them off square as there is enough room to do that with an oversize bolt thread.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 24, 2016, 03:18:10 AM
Very nice Mr. Willy!

I always enjoy your work.

Dave
Hi Dave, it is not my work really ,i am just copying someone else's work from 180 years ago !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 25, 2016, 07:59:51 PM
more work on the governor drive train.......the bearings made and fitted next is the gov itself and the pulley part
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 25, 2016, 08:13:51 PM
Very nice!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on February 26, 2016, 12:03:48 AM
Looks good to me Willy, as long as your happy with it......... :ThumbsUp:

 8) Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on February 26, 2016, 01:21:23 AM
Very nice Mr. Willy!

I always enjoy your work.

Dave
Hi Dave, it is not my work really ,i am just copying someone else's work from 180 years ago !!

And a very nice job you are doing of it!

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 28, 2016, 02:29:19 AM
done a bit more, the Governor pulley, and the A frame adjusting lugs for the wedges.....Also have just been given 66 tins of nuts screws washers and bolts,taps and dies.......mostly old school whitworth and BSF so if anybody local wants any then i will pass them on......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 03, 2016, 02:28:25 AM
more work on the governor, i have used square stuff so i could turn the 10BA thread and the extra length is to enable the part to be filed. This governor is a quite simple watt type with a minimum of parts so will be quite easy but a lot of filing. The finished dimensions are .065 " wide and .035" thick.Also i am still not too well with my asthma condition so have lots of new medication to take.....exept i am not allowed to drive or use tools and machinery !!!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on March 03, 2016, 11:13:49 AM
The filing job looks awesome.
The meds not so much.
Is the asthma a seasonal thing? Hope you improve soon.
Don't need the driving...but the tools and machinery? That's sad.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 09, 2016, 01:48:10 AM
Am feeling a lot better now so have done some more turning and filing on the governor......so need to catch up with drawing and finishing off the governor and then making the main and beam bearings........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 09, 2016, 02:51:05 AM
Looking good - glad you are feeling better!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 10, 2016, 12:35:26 AM
the governor is put together and installed but needs quite a bit of tidying up, that will have to wait as i need to proceed with the other bits and pieces
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on March 10, 2016, 12:54:44 AM
Looking good Willy and glad your feeling better mate. Governor looks great....... :ThumbsUp:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 11, 2016, 03:15:23 PM
Have now started on the main bearings, fairly standard apart from the brasses being 0ctangular and without flanges. There is possibly a part of the casting that prevents them moving sideways but can't see anything. The steel is marked out and the holes drilled for the bolting curved parts. The curves at the bottom are drilled out and to stop the drill bit wandering the holes are temporarily filled with a turned piece of steel which is removed afterwards.Photos of the bearing and an old one of the top bass removed.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 11, 2016, 04:01:03 PM
Interesting, never seen hex bearings before, still watching your build with great interest!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Johnb on March 11, 2016, 08:45:59 PM
"There is possibly a part of the casting that prevents them moving sideways but can't see anything."

Looks to me like the brasses fit over a reduced diameter of the shaft so there is a shoulder on the shaft either side of the brass. Am I mistaken? Would the whole shaft/crank/flywheel tend to move from side to side? Would the clamping force of the cap be enough to hold the brass and hence the shaft etc? Interesting stuff. Thanks Willy.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 12, 2016, 08:25:53 PM
"There is possibly a part of the casting that prevents them moving sideways but can't see anything."

Hi John , Yes there is a reduced diameter on the shaft, I shall be there again on the 19th Aprill so will look closer for any lugs that might engage with the main casting. Most if this engine is seized solid, but they are restoring it slowly, .....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 12, 2016, 09:17:11 PM
Nice to hear they are working on restoring it - hardly anything like that has survived in the US.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 13, 2016, 02:14:28 PM
Continuing with the bearing blocks .......the waste is sawn away and the blocks filed to shape, the round rod is inserted and the top ends have grooves in them to hold them position. I normally silver solder these parts but this time i am using soft solder to see how that works. After they are soldered i flick off the excess  solder onto the floor, holding they parts with a pair of pliers. the Round parts are predrilled in the lathe for the bolts before soldering.The next job is to make the octagonal brasses and the holes to locate them........The top caps are sawn off and the soft solder seems to be quite strong enough to hold everything in place so far. The parts need to be filed to proper shape an also profiled as per originals.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on March 13, 2016, 04:08:40 PM
Willy, I'm a pretty clever guy when it comes to fabricating things but I have to say that while watching you build this engine
I have learned some really neat and new tricks when it comes to making parts look like their full-size prototypes. I congratulate
you on your inventiveness!!

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 15, 2016, 03:34:23 AM
The octagonal bearing is filed with the 2 hole filing rest using the 60 tooth bull wheel in the Myford headstock, however, 60 divided by 8 is 7.5............................. so the ident for the bull wheel is filed at 90 degrees to straddle the gear teeth as well as sitting between them. This enables 120 positions to be used............ The bearing brass is turned with a taper to enable the octagonal slot in the Bearing block to be filed out. The slot is not that close fitting however so i will use soft solder as a caulking medium........Also a pic of me stuck in the motion work.                   
Willy, I'm a pretty clever guy when it comes to fabricating things but I have to say that while watching you build this engine
I have learned some really neat and new tricks when it comes to making parts look like their full-size prototypes. I congratulate
you on your inventiveness!!

Pete

Thanks for the comment, however i am just copying the original and using bar stock rather than wood as would have been done to make these " castings" as per the original
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 18, 2016, 12:37:19 AM
more pics and work on the other bearing block. The bottom bearing half is held in position with an 8BA countersunk screw and the top curves are milled out in the lathe.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 23, 2016, 08:07:18 PM
back at work after doing my back in ..planting asparagus......now i have to wait 3 years for them to be harvestable..........The beam bearings are made next ,T he foot is quite wide to fit on top of the A frame, so the base and upright parts are made in two operations . The round bolting flanges are drilled in brass stock and to keep the curved detail it is made as normal bearings. After the round parts are soldered in, the base is sawn off and filed as close to the curved details as possible. the base is drilled and attached with an 8BA screw to the upright part and soldered in place. The bar stock that is in the vice is almost sawn off to reduce the heat transfer into the vice. The next gob is to file to length and mill out the top curved details. The beam shaft actually covers completely the actually bearing so i cannot see if there is a separate hexagonal block. so it may be just steel onto cast iron. As i have made this item in brass i shall just drill and ream them.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 23, 2016, 08:25:40 PM
Nice!

Interesting that the joint at the bearing on the original is not at the widest spot on the shaft, which is how I assumed they always were done. Any idea why? Possible that it has worn downwards over the years and they shortened the cap? Though that would change the rod lengths below too...?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on March 23, 2016, 09:28:26 PM
..planting asparagus......now i have to wait 3 years for them to be harvestable..

I'm going to have to keep T away from this thread. She loves asparagus...me not so much.

Following along Willy.  :popcorn: It's a cool thread.

[EDIT: had the wrong name. Sorry about that.]
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 23, 2016, 11:09:57 PM


Interesting that the joint at the bearing on the original is not at the widest spot on the shaft, which is how I assumed they always were done. Any idea why? Possible that it has worn downwards over the years and they shortened the cap? Though that would change the rod lengths below too...?
[/quote]    Hi, I think the reason is ,as with the crankshaft bearings the two halves of the brasses are kept in position in the main block. As the top of the bearing is only held in position with two not very precision bolts there could be some sideways movement. On later engines the top block is made to fit exactly over the bottom block and this prevents any side ways movement. Here is a photo of a later beam engine that shows this type of construction. Thanks for the interest.
Willy........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 24, 2016, 12:02:13 AM
Thanks! Interesting detail.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on March 25, 2016, 12:45:31 AM
It's just fascinating how much details where put into these engines. For the equipment they had to work with, you think they would of skipped the details. Your really doing a great job of transforming it into a model Willy.

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 25, 2016, 12:58:52 AM
It's just fascinating how much details where put into these engines. For the equipment they had to work with, you think they would of skipped the details. Your really doing a great job of transforming it into a model Willy.

Don
[/quote]

Hi don, yes there are lots of great details and as it is from the 1830's it follows lot of the architecture of the period.  I have been exploring a local waterworks building that had three beam engines in it and they are even more ornate with some of the details......Almost a Cathedral to sewerage !! The building is now empty and derelict and the only thing left is the spiral staircase.....Enjoy.......
willy
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 25, 2016, 01:08:44 AM
a few more pics of the bevel gear drive to the Meyer Type valve gear etc
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on March 25, 2016, 04:08:25 AM
I just love those old drawings! It's art and engineering and history and they're just amazing and wonderful.

Thank you!!

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 27, 2016, 04:06:38 AM
The beam bearings are finished and just need fitting. next is the Beam itself which will need some intensive thinking about to get it looking correct with all those mouldings.................
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 27, 2016, 11:46:39 PM
Pictures of the engine so far..............
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on March 28, 2016, 12:06:55 AM
Nice!

 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on March 28, 2016, 01:02:28 AM
Hi Willy,
 She's coming along rather well! Loving your fabrication & filing work.

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: joe d on March 28, 2016, 01:13:42 AM
Looking good, Willy.

I am really enjoying following along.

Joe
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on March 28, 2016, 01:32:40 AM
Looking sweet Willy............ :ThumbsUp:


 :wine1:
Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on March 28, 2016, 03:08:15 AM
Amazing work Willy!

Thanks for keeping us updated on your latest project.

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Johnb on March 28, 2016, 08:25:26 PM
Cracking job! Keep up the great work.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 29, 2016, 12:38:11 AM
The beam is now tackled and it has been drawn up and measured. the cavetto mouldings will be quite challenging and also the detail at the end of the beam......Quite easy with a sharp gouge into wood but a different story with metal !! here are pics of the rusty Beeleigh engine and a contemporary one ensconced at the Ramm Brewery in Wandsworth London. Thanks for all the comments, it is very encouraging to receive them...cheers
Willy........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 29, 2016, 12:59:31 AM
Those are going to be challenging to build up, looks like the vertical crank arm too. Would it be possible to make an inner metal beam core, with applied moulding over the sides? If you carved the moulding in wood, make a rubber mould and cast them in epoxy or polyester resin?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on March 29, 2016, 03:10:23 AM
Yes, quite a challenge; it will be fun to watch how you go about reproducing the beam on this amazing piece of history. How ever you choose, I'm sure that it will be as amazing as the rest of the model.

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on March 29, 2016, 11:54:00 AM
that beam is a challenge isn't it.

I was thinking about how to do that the other day ( for when I eventually do one myself) I came up with a few ideas. none of which are easy


making it all in individual parts then assembling it is probably the easiest to get right and would follow with the rest of the construction


Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 30, 2016, 01:00:38 AM
that beam is a challenge isn't it.

I was thinking about how to do that the other day ( for when I eventually do one myself)
Hi Bertie, Thanks for the ideas, I am still thinking how to go about this however trying to use bar stock and imperial and metric tooling is a challenge in itself, i may be using a certain amount of filler to get the correct profiles...........we shall see.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 01, 2016, 01:37:33 AM
Have started with the beam........drawing and getting coordinates right. a test piece for the outside beam flanged has been milled out using a 3/32 and 1/16 ball end cutters. these are really tiny so the paint will possibly hide these features !! It is quite tricky getting good photos on my camera so i take about 20 pics at all different angles and lights and try to get the best shots !
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on April 01, 2016, 03:02:11 AM
 Willy I admire your hand drawings mate, first class as is your fabrication work...... :ThumbsUp:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 01, 2016, 03:50:24 PM
Willy I admire your hand drawings mate, first class as is your fabrication work...... :ThumbsUp:

Don
 Hi, Its amazing what a bottle of tippex can do !!!!
Willbert
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on April 01, 2016, 11:27:53 PM
looks like good progress
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: fumopuc on April 02, 2016, 06:08:11 AM
Willy I admire your hand drawings mate, first class as is your fabrication work...... :ThumbsUp:

Don
 Hi, Its amazing what a bottle of tippex can do !!!!
Willbert
OK Willy, but what to do if the whole screen of your monitor is painted with tippex ? :lolb:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 03, 2016, 01:55:31 AM
The outside flanges are milled out and sawn off. they will have to be profiled after they are soldered to the central web.....                   
Quote from: fumopec
OK Willy, but what to do if the whole screen of your monitor is painted with tippex ? :lolb:
[/quote

Easy find a new monitor..........just look in the nearest skip......People in Norridge do post things on Facebook when they see them in skips !!!





Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: fumopuc on April 03, 2016, 06:08:45 AM
Willy, I like your fabrication work and your humour.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Roger B on April 03, 2016, 08:43:18 AM
Still following along and enjoying the fabrication work  :ThumbsUp:  :ThumbsUp:  :wine1:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on April 03, 2016, 12:18:16 PM
Fascinating thread Willy.
Excellent work and seeing pics of the prototype is a real treat.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 03, 2016, 01:57:53 PM
Fascinating thread Willy.
Excellent work and seeing pics of the prototype is a real treat.
Hi I do have about 700 pics of this engine and what i have found is that pics of the spaces in-between are just as important as the component parts themselves, also i try to take 1st and 3rd angle projections of the parts as in drawings. it is also useful to have a ruler in the photo !!Thanks for the interest
Wilhelm....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 05, 2016, 12:16:42 PM
the other side flange of the beam is made and drawings drawn for the other parts The central web detail is actually called the feather. Also the connecting rod is called the sweep rod sorry about being pedantic but like architecture every change in direction of a surface has a new name ....corbals architrave quoins purlins stile muntins  etc etc etc. Also found a big heat sink from a piece of electrical gear i was recycling and found it makes a good drilling aid.......I have also extended the side handle to make raising and lowering the headstock easier.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 06, 2016, 01:14:41 AM
I am waiting for some more brass to arrive so i have been catching up with the perspex proving model.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Intheshed on April 06, 2016, 01:48:16 PM
Hi,
many years ago, I was a driver/operative for a woodworm treatment company and we were called to treat Beeleigh Grange, the most haunted house in England and made almost entirely of wood, a most unusual thing for a fine house.
Wish I'd known about the engine there!

Cheers,
Martin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 06, 2016, 04:50:36 PM

Hi,
many years ago, I was a driver/operative for a woodworm treatment company and we were called to treat Beeleigh Grange, the most haunted house in England and made almost entirely of wood, a most unusual thing for a fine house.
Wish I'd known about the engine there!

Cheers,
Martin
[/quote]
Hi Martin, this is a map of where the engine resides. It is totally off the beaten track and almost completely surrounded by water and what with the corn laws etc etc has escaped the attentions of anybody that may have had any nefarious interests with it
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 06, 2016, 05:57:33 PM
Corn laws? Your crops have laws?!

Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Intheshed on April 06, 2016, 07:02:12 PM
Oh yes, crueby!  Look em up.

Just up river from there is the Museum of Power at Langford.  Full of engines.  Worth a visit.

Martin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 06, 2016, 08:45:29 PM
slowly working out how i am going to do this....................the acorn ends will be turned up and then slots milled in them to slot the beam into and then soldered together. The beam will then be filed to the contours of the acorns. vis.............this is only a test piece at the moment just to see how it will work .the difficult bit is the scalloped detail.........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 06, 2016, 09:09:22 PM
Clever solution - going to be a great looking engine.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Intheshed on April 06, 2016, 11:46:59 PM
How will you do that lattice work on the drop beams?  I notice it isn't exactly even on the real one!

Martin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 07, 2016, 02:19:09 AM
the beam bar is milled from a piece of 1" x1/8" brass bar, it is 3/32 " thick so 1/32 is removed. the milling marks are removed by filing with a 3 square file. the wooden handle is taken off and the file held on the top with the fingers  at a slight angle . this makes it easier to file very flat.
When the brass was removed it sprang into a banana shape. this often happens with steel as it releves the tension but i have not noticed it with brass before. I will have to heat it up and see what happens. Perhaps it should have been annealed before milling. has anybody had this happen and any advice to make it dead flat again ?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 07, 2016, 03:15:23 AM
I have had that bending happen a lot with flat bar brass. Best prevention is to heat it in the oven at 500f for an hour and let it cool. That relieves the stresses that were introduced when the brass was rolled out in manufacturing. Without it, if you cut down one side it will spring into a curve. If you take an equal amount off both sides it can even out. Once curved it is very hard to straighten, I don't think heating it after cutting will help, but I have not tried it. After several times that it happened, I now stress relieve all stock that I will be cutting down. It happens on both flat and round bars. Turning on a lathe doesn't show the curve since you are taking an even layer off all around.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 07, 2016, 07:15:40 PM
thanks Crueby, I heated it up and just pushed it down on the fire brick and squished it in the vice and it came strait again. However when i returned it to the piece of steel to hold it firmly for marking out it seems to have shrunk a bit..........Also the brass has a matt finish that will make it easier to photograph.   also when brass is annealed it is softer so is it easier to cut until it work hardens again saving energy ??!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Intheshed on April 07, 2016, 07:34:13 PM
Why would you mill that bit off when you could have started with 2mm brass?  That can be had from engravers as off-cut.  Or, if pushed you can get it from brass suppliers in small amounts.
I have made brass patterns for the white metal model kit industry for years and never had the bending issues.  But then mostly I was hammering it into shape.

Martin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 07, 2016, 08:29:52 PM
thanks Crueby, I heated it up and just pushed it down on the fire brick and squished it in the vice and it came strait again. However when i returned it to the piece of steel to hold it firmly for marking out it seems to have shrunk a bit..........Also the brass has a matt finish that will make it easier to photograph.   also when brass is annealed it is softer so is it easier to cut until it work hardens again saving energy ??!!

Glad you were able to save the piece. I've had the bending problem a lot on thicker bars that were harder to reflatten, so have gotten in the habit of stress relieving the brass stock for an engine before cutting. Just takes an hour in the oven, and does not change the hardness. From what I've read, for most steels the temperatures needed are much higher so can't be done so easy.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 08, 2016, 02:19:30 AM
so, i am taking the plunge and starting on the beam proper......i have made a new acorn and milled the slots for the web as well as the feather. I have sort of filed the scalloped bit but it will need further work to look right. the acorn has been soldered on and the web filed down to match the acorn.......seems to be going ok so far......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Johnb on April 08, 2016, 10:05:55 PM
Plunge well taken Willy. I'm looking forward to this bit. Many thanks.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 09, 2016, 04:19:40 PM
The acorn ends and the bosses will be turned up on square stock to enable the milling of the slots to be indexed easier, a pic of the individual parts to be made 30 in total !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on April 09, 2016, 04:30:50 PM
30 of them!  :o

Looks excellent!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on April 09, 2016, 07:44:55 PM
looking great! keep up the good work!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 09, 2016, 08:03:54 PM
30 of them!  :o

Looks excellent!

Not so bad Zee, he has a larger parts-to-banter factor...!

Looking fantastic as always Willy!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on April 09, 2016, 11:35:27 PM
Lovely work Willy ............ :ThumbsUp:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 16, 2016, 02:08:06 AM
Back at work after i lost the first beam part.....so i had to get another piece of 1/8 brass bar and mill  it down ,make two new acorns and solder them in. Only 26 more pieces to make now. i have also been busy with somebody bike shortening the pedals and other stuff. I am going to the mill at Beeleigh  on Tuesday to get more measurements. and photos. thanks for all the comments as well......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 17, 2016, 03:00:53 AM
have made some more bits and a soldering jig for the web flanges etc...... it also makes a good assembly jig. once the flanges are int place the other parts can be made to fit I will glue the feather and lugs in place as there will be minimum load on these parts......there will be a lot od filing to merge all the parts together and there will be quite lot of filler needed.........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 17, 2016, 03:05:11 AM
have made some more bits and a soldering jig for the web flanges etc...... it also makes a good assembly jig. once the flanges are int place the other parts can be made to fit I will glue the fatherland lugs in place as there will be minimum load on these parts......there will be a lot od filing to merge all the parts together and there will be quite lot of filler needed.........
What are fatherland lugs?

Looking great!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 17, 2016, 03:11:18 AM
Hi Creuby , sorry ,that should be feathers and lugs.  Feathers are the correct name for the length way flanges that run down the middle of the beam web. It is 3am over here so i am a bit tired after a hard days work !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 18, 2016, 12:27:08 PM
More on the beam ,i have now discovered the macro button on my camera and so here is the picture of the beam end....i soldered the flanges and the circular end piece that connects them at the same time so did not quite get the alignment in the correct place. Now i have the jig and the flanges soldered in place i can measure and turn these pieces to fit accurately before attaching them ....hopfully..... I am going down to Beeleigh Mill again tomorrow to get more photos and measurements. They are also trying to remove the bolts to the air pump that pumps water!!  these are proving to be quite stubborn and the millwright has suggested freezing them with plumbers spray to remove them with out mishap !! will try to get some photos of that too
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on April 18, 2016, 07:55:34 PM
Willy that look ok to me mate and still with you till the end....... :ThumbsUp:

 8)  Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 23, 2016, 01:24:21 AM
have done some more on the beam......the bosses have been turned  and the feather slots filed up. i have been busy in the allotment now the weather is improving........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 23, 2016, 01:47:24 AM
The beam is coming together nicely!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 24, 2016, 02:20:15 AM
I have made all the bosses and the curved end pieces and now have to solder them on in the correct alignments and make the feathers to fit then it is finished !!........looks like you are all having a good time at NAMES..we have a similar thing at the Forncett steam museum here in Blighty where quite a few of us attend.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on April 24, 2016, 02:31:33 AM
Are you in the pic?
It'd be good to know.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 24, 2016, 02:50:06 AM
Good looking group, of parts, people, and models!

I think that is Willy behind the bow of the boat??
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 24, 2016, 03:07:20 AM
Are you in the pic?
It'd be good to know.
Hi, I am 4 from the right and Sco is 2nd from the left....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on April 24, 2016, 04:06:20 AM
Ah! That is great to put faces to the names. Cool.

Looks great.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on April 24, 2016, 11:40:57 PM
Hi Willy

The beam is coming along nicely, thanks for posting the update.
With regards to the group shot; What a nice looking bunch of folks and I actually recognize some of them.  :lolb:

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 27, 2016, 01:28:54 AM
i have started on the feathers and fitting them so it is going to look ok after filling etc. Have looked at the NAMES event and lots of good work there, also quite a lot of large models ,but then everything in America is bigger !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on April 27, 2016, 11:53:40 PM
Willy that beam is looking sharp and the mug shot is not bad either....... :lolb:


 8) Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 28, 2016, 01:56:35 AM
the beam is coming on and brainwise is finished !!!  I have made clips to hold the curved parts in place whilst soldering the feathers and bosses on the web and all is going well. I have to remake some of the parts to get the cavetto profiles to fit........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on April 28, 2016, 02:25:04 AM
Willy you are the master!

The beam looks splendid.

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 28, 2016, 02:48:07 AM
Very nicely done!!

Do you solder low temperature or silver braze these kinds of parts?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 28, 2016, 03:37:30 PM
Very nicely done!!

Do you solder low temperature or silver braze these kinds of parts?
Hi, i used to solder with silver solder but have found with the lighter loads on small items soft solder is perfectly adequate. I use the resin multicore solder as used in electronics rather than plain plumbers solder as this is now lead free and not as viscous. I get old reels of solder from car boot sales as this a cheap way of obtaining same. i may use superglue of the outside feathers as these will be rather more difficult to solder without mis hap...........I don't know what the temperature difference between lead free and electronic solder is ,but it would be interesting to find out for subsequent soldering of components....any one got a computer ?? !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 29, 2016, 01:21:05 AM
I have been busy now i know what i am doing and this side of the beam has all the parts in place......just needs lots of fettling and filing and filling and finishing and the other side doing......phew that was an epic task, but in the end it turned out ok,   except all the detail will vanish under the paint!!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on April 29, 2016, 01:23:32 AM
Just OK!

You need to give yourself a little more credit; that is an amazing piece of work my friend.

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 29, 2016, 01:58:31 AM
Looks terrific! Going to be a wonderful model to watch run.

Hard to get a sense of scale (sign of good work) - how large is that tower and beam?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on April 29, 2016, 02:31:08 AM
Awesome work Willy.......I..........like............ :Love:

 :ThumbsUp:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 29, 2016, 02:33:42 AM
Looks terrific! Going to be a wonderful model to watch run.

Hard to get a sense of scale (sign of good work) - how large is that tower and beam?
   Hi, This is a better photo with the ubiquitous coke cans for size......I'm glad you like the work so far as i don't want to let the side down ....the con rod will be next and then the steam  jacketed compound cylinders....that will be the biggest challenge !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on April 29, 2016, 03:20:22 AM
How appropriate! The can on the right is smaller.

Seriously though...happy for the pic. Looking good.
At some point you'll need a pic of the real thing behind the model. That would really tell the tale of the work you're doing.

 :ThumbsUp:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 29, 2016, 01:12:59 PM
How appropriate! The can on the right is smaller.

Seriously though...happy for the pic. Looking good.
At some point you'll need a pic of the real thing behind the model. That would really tell the tale of the work you're doing.

 :ThumbsUp:
Hi, Zee,.....here are some pics of the engine, some historic and some more recent, as they are restoring it they have built some wooden superstructure around it, and as it is in quite a small space it is quite difficult to get a photo of the whole engine........they flywheel is 15 feet diameter and actually protrudes into the wall on the far left !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on April 29, 2016, 03:08:56 PM
Nice. Thanks. I don't think I'd seen the one of the building.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Johnb on April 29, 2016, 09:55:15 PM
Very nice Willy. Keep at it. It's great.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 30, 2016, 01:05:07 AM
Nice. Thanks. I don't think I'd seen the one of the building.
  hi Carl this is the "front" of the building and everything has to go in and out of the very narrow doors. there is also the Elephant boiler that is in quite good condition insofar that it is complete with all the fittings. This boiler will not be steamed however and the plans for a new boiler system has been drawn up.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 30, 2016, 01:59:56 PM
Oh Dear , calamity, measure twice cut once......!! actually ..measure thrice ,look at thrice, calculate thrice.....etc etc etc.....After looking at the new photos from Beeleigh using the wooden non reflecting ruler i thought some of the bosses were not in the correct place......!!! and yes one of them is ,by about 1/10" so i am going to move it. Luckily i noticed it before i assembled the feathers on the rear of the beam so it will not be too difficult to remelt the solder and reposition them........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 02, 2016, 12:32:44 AM
the beam boss has been removed and the hole drilled in the correct place.......also went to the local old pump station at Trowse and after clearing away the ivy found this window with the large air ejector inside. I think this is a large tank full of air ,and when the engines pump the sewerage into it through a valve the air compresses slightly and sends the effluent on its was to Wittllingham sewerage works several miles away.....vis....this is the only part of the 1872 system that is still there !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on May 02, 2016, 02:20:10 AM
That is pretty cool.
Discovery is fun.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on May 02, 2016, 02:21:35 AM
Glad you caught the mistake before too much of the rest was done. Going to be a great model!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 03, 2016, 02:32:45 AM
The beam has now been changed to the correct boss positions and now just needs the shafts and filling to merge all the contours together.....i have been thinking about the beam since 2 October 2014 !!! when i first visited Beeleigh mill, and it is a bit of a relief now it is finished after worrying about all those contours.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Johnb on May 03, 2016, 08:31:38 PM
"i have been thinking about the beam since 2 October 2014"


Those sleepless nights have paid off!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on May 04, 2016, 02:28:23 AM
Impressive work Willy!

Looking forward to more.
Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 04, 2016, 08:30:54 PM
"i have been thinking about the beam since 2 October 2014"


Those sleepless nights have paid off!
    Actually, John, the way i made it is possibly the same way they built up the wooden  pattern !!  Am struggling with chronic toothache aT THE MOMENT SO AM OUT OF ACTION FOR A WHILE.......And Dave... impressive depends on how close you look at the details !! also i am going to investigate  solder paste. I have a large quantity of solar and flux that i am using up ,but paste will be a lot cleaner in use so i am told.......also i would go about the construction in a different way if i make another........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on May 04, 2016, 09:36:59 PM
ahh, good old ejector pumps. got to be the only pump still made that sounds like a steam engine!

an ingenious design but I never really got on with them, too noisy and overly complicated.

the ones iv worked on looked like a large compressor tank but actually had a wall in the middle separating it into 2 tanks, one for vacuum and the other for compression. you suck up the sewage into the vacuum chamber whilst filling the compression chamber then when both are full you dump the compressed gasses back into the vacuum tank forcing the sewage back out and up the line.

we were always getting blockages in to non return valves thus sending the sewage back into the well! either that or the float valves would fall off and the compressor would suck up liquids. also very very prone to fatting up as they worked so slowly and in pulses.

anyways back to your fantastic work on the beam -  looking great as usual. ill have to pop into the museum at some point, drove past it last week but didn't have the time.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 05, 2016, 01:08:53 AM
ahh, good old ejector pumps. got to be the only pump still made that sounds like a steam engine!

an ingenious design but I never really got on with them, too noisy and overly complicated.

the ones iv worked on looked like a large compressor tank but actually had a wall in the middle separating it into 2 tanks, one for vacuum and the other for compression. you suck up the sewage into the vacuum chamber whilst filling the compression chamber then when both are full you dump the compressed gasses back into the vacuum tank forcing the sewage back out and up the line.

we were always getting blockages in to non return valves thus sending the sewage back into the well! either that or the float valves would fall off and the compressor would suck up liquids. also very very prone to fatting up as they worked so slowly and in pulses.

Hi Bertie, thanks for the info i shall have to look into this a bit more to try and understand exactly how it works with this set up. The Beeleigh engine in Maldon is open for the working team on Tuesdays after 1,30 pm , and the Beeleigh Mill Restoration Group   have a website on the web for other info. thanks for the info and have more pis of the Trowse engine showing the ground plans and other aspects  of the engine. These drawings are held in the County Hall archive section.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on May 05, 2016, 09:17:16 AM
ejectors are quite simple once you've got your head around them. there is quite a few still working in the Anglian area, not as old as the one you've found but still a fair age
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 05, 2016, 10:36:37 PM
the 2 beams. together thanks 2  Clare
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on May 06, 2016, 01:39:09 AM
 :ThumbsUp: :ThumbsUp:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 06, 2016, 12:01:10 PM
Here is a pic of the engine with a scale Hepplewhite contemporary chair to give an idea of scale........also for the denizens of Norridge and its environs, Class Olsen in Chapel field is closing down on June 5th and everything is 40% off at the moment..........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on May 06, 2016, 05:10:00 PM
looks like things are coming together very well indeed!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 10, 2016, 11:55:25 PM
a bit more on the beam............i have made a clamping jig to drill the end holes square, the next job is the bolting stubs for the motion hangers....Also i was in this cafe with a tips bowl, i wondered how much to put in and decided it was a matter of a pinion........1
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on May 11, 2016, 12:37:57 AM
Nice work on the beam!

Also nice pun!   :Lol:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 13, 2016, 03:22:45 PM
am now thinking about the beam bearing stubs ,On this engine and the similar Wandsworth example the stub shafts seem to have covers on the motion ends but not on the sweep rod ends. The bolts holding on the covers are very small indeed and perhaps these covers were made to make assembly a bit easier. The other parts of the motion do keep the hangers in place however so perhaps these small bolts are enough to keep things ok.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on May 13, 2016, 07:31:59 PM
Those covers are interesting. Looks like one side has square stubs sticking out, the other side is sunk in on all of them. Are they actually covers, or is that just the ends of the axles, with remnants of what was used to hold in a lathe for turning them, maybe? If covers, wouldnt both sides be the same?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 14, 2016, 01:36:00 AM
I have started on the motion work ,I have made the mock up hangers to see how they go together. the bottom holes are for the parallel motion strap and the other holes are there to make the parallel motion work properly........on the high pressure piston and air/waterpump rods. this is worked out by a strait line from the outer piston rod to the centre of the beam bearing. this is why the motion work looks so complicated. With only one cylinder the cylinder rod will rise and fall vertically but with 2 cylinders and the air pump the geometry is totally different, but easy to work out. On this engine they did not quite draw the parts correctly so to allow the air pump to have the clearance to work they had to chip away some of the beam !!!This can be seen in one of the pics, there is another pic of an engine where the beam has been modified to take this into account.[quote
Those covers are interesting. Looks like one side has square stubs sticking out, the other side is sunk in on all of them. Are they actually covers, or is that just the ends of the axles, with remnants of what was used to hold in a lathe for turning them, maybe? If covers, wouldnt both sides be the same?
 Hi, Crueby, as i cannot take any bits off i will have to assume they are separate covers, the sweep rod shaft seems to have very little "meat" on it to be a separate cover.......we shall see.....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on May 14, 2016, 01:54:13 AM
Nice to see that they made simaler clearance goofs on the real engines tbat we do on the models sometimes! Guess that they did not make the clear plastic mockups like you have.

Great progress!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 14, 2016, 02:21:24 AM
Nice to see that they made simaler clearance goofs on the real engines tbat we do on the models sometimes! Guess that they did not make the clear plastic mockups like you have.

Great progress!
Just found this pic of the Wentworth engine with the same beam alteration but in a much tidier fashion........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 17, 2016, 12:29:02 AM
i have started on the crank. It is made from 3 pieces of 1/8" steel plate silver soldered together. I have made filling buttons to file the round profiles to
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on May 17, 2016, 01:20:58 AM
Wow - even the crank web is ornate! Is the original a cast piece? Seems like it must be. Some back room somewhere had some great wooden masters for all these parts - if only we could find it!

 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on May 17, 2016, 01:34:07 AM
Wow - even the crank web is ornate!

Yeah. The early machines were works of art. Particularly, in my mind, the UK.
Must have been the bean counters, nay, stockholders, that put an end to that.
Sad.

I say the UK in today's thinking. You all know what I mean.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on May 17, 2016, 03:43:14 AM
The engineers of that era were, especially by 1890, classically trained and were versed in classical art and architecture.
It was exhibited in everything they designed and built from major engineering works to houses. The era produced some
of the most wonderfully artistic work since the Greeks.

The Arts and Crafts movement was a reaction to that ornate display and by 1910 the era was one foot in the grave.

I guess that after the Great War the focus was more on quantity than ornate decoration... too bad.

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 18, 2016, 11:26:06 PM
more on the crank the 3 parts cut out and nut and bolted together to solder. The rear part is actually tapered but to keep it in position when soldering ,it is extended all the way along and bolted with the front part. This will be filed down afterwards,......Also the Two hole filing rest has appeared in the Model Engineers Workshop Magazine. this was submitted about 3 years ago !! so things do get published eventually........Also can anyone identify this piece of metal....it is very heavy about 3/4 " wide and 1/8 deep with lots of holes drilled in it........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 21, 2016, 02:43:46 PM
The crank is now in position with the rear web filed off. I am now drawing up the sweep rod/con rod and figuring out out to make it from bar stock of course......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 25, 2016, 01:39:05 AM
I have started on the sweep rod and after measuring the beam and crank centres there was a difference of about 4" from the Beeleigh mill engine......only about 3% so not too bad. I have used a square piece to start off with as it is easier to mark out and machine. The middle webs will be made separately and soldered in place. the top bearing housings will be made from steel that will be polished whilst the bottom and middle part will be painted. I am not too sure about how the brasses are made as the straps are not open at the ends so they cannot be slid in.  I may have to round off the inside parts so the can be inserted sideways, then twisted 90 degrees to line up. This will leave the brasses with not much metal inside.  any ideas will be helpful ...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on May 25, 2016, 02:18:20 AM
Willy great details mate and I do enjoy seeing your drawings ............  :cheers:


 8) Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 26, 2016, 01:22:21 AM
a bit more work on the sweep rod and seeing how it will fit with the rest of the engine and a few more adjustments still need to be done
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on May 26, 2016, 01:38:55 AM
Willy great details mate and I do enjoy seeing your drawings ............  :cheers:

Yes! What Don said. I also enjoy seeing the pics of the original.  :ThumbsUp:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 26, 2016, 02:01:26 AM
Willy great details mate and I do enjoy seeing your drawings ............  :cheers:

Yes! What Don said. I also enjoy seeing the pics of the original.  :ThumbsUp:
Hi, I do have about 700 photos now, but still need more !!!!! but as it is such a confined building, plus the wooden walkways it is quite difficult to get a full on frontal pic......I am actually quite enjoying this build now as it is slowly coming together.....and the more bits that get done the less there is. The engine will be tackled soon and this will be the greatest challenge, however once in the workshop everything seems to happen !! A mirror is quite useful for some of the pics as well. I do look quite happy in one of the pics...but then who wouldn't given the chance of getting close up to an 1830's engine and having totally free access to all ares without any supervision !!..Thanks for all the comments and encouragement as well.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on May 26, 2016, 02:09:37 AM
I do look quite happy in one of the pics...but then who wouldn't given the chance of getting close up to an 1830's engine and having totally free access to all ares without any supervision !!

Indeed!  :ThumbsUp:

Nearly two hundred years! It's fantastic.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 27, 2016, 12:08:42 AM
I have worked out how to assemble the bottom sweep rod parts and have made a model to test it out........The slot is first cut out making sure there is enough room to insert the bearings from a sideways position . a small amount is removed in a curve to allow the bearings to swivel into position. a block , white, is then inserted to wedge the bearings together and the top plate bolted on. there is a bolt at the bottom to take up any slack. .........easy really......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on May 27, 2016, 01:27:28 AM
Clever!

Quote
.........easy really......
Everything is easy once you figure it out! Time travel took a while...  :Lol:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Johnb on May 28, 2016, 08:21:25 PM
Elegant solution!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 02, 2016, 02:16:04 PM
Am now back at work after Strumpetshaw steam museum gathering.........Have made the bearings and keep plates for the bottom sweep rod bearings. I drilled the holes in the top keep plate first then glued it in position on the sweep rod to get the alignment correct to drill through the inside block. I left the glued plate in position to file it to thickness as well.......the securing bolts are 16BA !!.....I have also made a start on the rod webs.....they are cut out of brass leaving dowels in the width to insert in holes drilled in the rod prior to soft soldering.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 02, 2016, 02:58:04 PM
Nice!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on June 02, 2016, 07:15:20 PM
Very intuitive Willy............. :ThumbsUp:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 03, 2016, 01:04:25 AM
Very intuitive Willy............. :ThumbsUp:

Hi Don , I think the only way to do it is think of it as a metal patten using solder instead of glue, which is a sort of hot glue i suppose !!,,Thanks for the comments......
willbert
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 04, 2016, 01:01:52 AM
The webs are now soldered in place on the sweep rod so just the top bearing assy to make and fit......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 04, 2016, 01:09:46 AM
That looks great!   :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on June 04, 2016, 01:10:58 AM
The rod turned out great!

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 06, 2016, 03:22:10 PM
More drawings of the sweep rod components.......I have been looking carefully at the photos and dimensions of the sweep rod but have found there are some discrepancies, so, i may make a new one and put this one on the acrylic model........I have been really under the weather the last few weeks and saw the doctor and he asked me if i did "soldering" !! he then sent me for an x-ray and i have cloudy lungs !! so he gave me 2 lots of antibiotics and am suffering from weird side effects.......any way the sun is shining and the allotment is looking great so everything is gravy........!!There is planing notice round the corner from me about the old electricity building and they are going to reinstall the heat pump into the building.....using the river as the primary source. And one of the model engineers used to work there and he said that all the brass pipes in the river are still there as well as the heat exchanger stuff !! So scuba diving and scrap metal merchants spring to mind !! but not with my lungs........ I also have a book all about commercial heat pumps with lots of photos of the duke street one............
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 11, 2016, 01:56:43 AM
more work on the top straps, the top parts are made of steel and the main part will be soldered to the sweep rod .the bearings are next and the straps need tiding up and attaching with gib and cotters.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 11, 2016, 02:03:18 AM
Some intricate machining on those parts, looking great!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Johnb on June 11, 2016, 09:05:46 PM
I'm intrigued by the brass bits as they look so similar to the steel straps. I'm looking forward to the next instalment see how it all goes together. Fascinating.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 11, 2016, 11:42:05 PM

I'm intrigued by the brass bits as they look so similar to the steel straps. I'm looking forward to the next instalment see how it all goes together. Fascinating.
Hi John ,The big square lump is the end of the square stock that is left when turning the sweep rod. It has been left to the last minute to return to the 4 jaw SC chuck to finish turning the socket arrangement (1BA thread) to attach to the top strap holder part. The threaded part where the adjusting screw at the bottom of the rod is located has the chamfer for the revolving centre to locate. The top strap bearings are turned up and the square part of the bearing is made from square  stock . As the saw cut is quite wide the two bearings are drilled and reamed and when sawn off ,the saw is offset to one side to leave a full half reamed portion.....There is now a lot of fettling and polishing to do and also the gib and cotters to fit..........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on June 12, 2016, 12:50:25 AM
Willy you continue to impress me with your fabrication work. Impressive results mate...... :praise2:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Johnb on June 12, 2016, 11:50:58 AM
Fettle on Willy! Wonderful stuff.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on June 12, 2016, 09:46:43 PM
thats coming along very nicely, keep up the good work  :ThumbsUp:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on June 13, 2016, 01:44:36 AM
Impressive work Mr. Willy!

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 15, 2016, 02:48:47 AM
I have started on the flywheel hub ,first the drawing then cutting out using hacksaw and angle grinder, the hole 1/2" is drilled and reamed. The outside is then turned using a sawn off 1/2" bolt in the collet chuck and bolted up tight. the slots for the spokes are milled out. I was going to use the rotary table but decided it would be quicker and just as accurate using a hex bolt and nut turning it round after each cut using the hexagonal datum . The cut outs of the hub are then positioned using the spoke marking out tool that i 'invented' !!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 15, 2016, 03:03:53 AM
Thats a very interesting spoke pattern, and an interesting marking gauge(s) too!

 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on June 15, 2016, 06:09:43 AM
That gauge is nothing short of brilliant!! A center square with an off-setting leg built in! How many time I could have used such a device........

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 15, 2016, 01:09:07 PM
here are some photos of the hub and flywheel arrangement, the spokes are separate to the hub and outer so it will be interesting to get everything to fit and run true.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 15, 2016, 01:16:40 PM
That gauge is nothing short of brilliant!! A center square with an off-setting leg built in! How many time I could have used such a device........

Pete
Hi Pete, er um yes er um I have finally got round to making this myself after 40 years of procrastination.......it is not copywrite or patented so please feel free to make one yourself !!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 16, 2016, 02:55:16 AM
More work on the flywheel hub . The two sides have been turned up and will be attached to the central part with a tube inserted in them. this tube will have a slot cut in it that will carry the keyway for the crankshaft.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on June 16, 2016, 03:00:03 AM
Gettin' better every week! And thanks for the additional information on the spoke gage.  :cheers:

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 16, 2016, 03:00:30 AM
That hub is great. On the original was it one cast piece?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 16, 2016, 03:16:09 AM
That hub is great. On the original was it one cast piece?
Hi, yes it is cast as one piece including some webs on the back that help support the bolts that hold the spokes in place. these will be soldered in place later.........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 18, 2016, 01:03:29 AM
Have started on the spokes now the hub is finished with the keyway insert. There is quite a lot of work now to do all the mouldings and get them all the same.......the holes are tapped 10BA and will be fitted with square headed nuts and bolts.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on June 18, 2016, 01:22:09 AM
The moldings on the spokes add more nice detail to this engine; the designers and pattern makers didn't hold back on this one did they, should keep you busy for a while? I'm looking forward to seeing more of the flywheel construction.

Dave 
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 20, 2016, 02:17:44 AM
the spokes have been fitted to the hub and the rear webs have been started.The round bolting parts will be bolted on with rusty bolts and then with the web parts, soldered in place, and once they are attached they will be filed to shape......Using the rusty bolts will mean they can be removed easily after the soldering.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 20, 2016, 02:46:16 AM
Great looking webs, I like the style they used. Can't wait to see the finished engine.   :popcorn:

Interesting technique with the rusty bolts. Wonder if you could get a government grant to study which type bolt, which garden to bury in for how long, etc!  :Lol:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 20, 2016, 03:21:55 AM
Great looking webs, I like the style they used. Can't wait to see the finished engine.   :popcorn:

Interesting technique with the rusty bolts. Wonder if you could get a government grant to study which type bolt, which garden to bury in for how long, etc!  :Lol:
Hi , if we are still in the EU after Thursday i may apply for a grant from Europe !!!!

Um, ignorant question, more time recently outside than watching the news: what happens Thursday? You guys joining South America?!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 20, 2016, 02:40:22 PM
Big doings! Makes you want to go back to the shop and build something real!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bluechip on June 20, 2016, 03:30:37 PM
Big doings! Makes you want to go back to the shop and build something real!

Doesn't it just ...  ::)

The electorate is supposed to make an objective decision based on lies, half-truths, threats, promises etc. from a bunch of self-serving, nepotism-infested grasping bunch of incompetent charlatans in one camp or a polar opposite set of lies, half-truths, threats, promises etc. from a bunch of self-serving, nepotism-infested grasping bunch of incompetent charlatans in the other camp.
Nice to be offered the choice though.  :praise2:

This South America idea seems to have some merit ...  :ThumbsUp:  I think we should go for it ... Rum any cheaper there I wonder ??

Dave

Apologies for being political, off topic, ranting etc.  Off to continue my sulk 'cos my bits haven't arrived from R.S.  :'(

Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Jo on June 20, 2016, 04:51:24 PM
 :offtopic:

Guys lets stick to discussing making our models rather than the political challenges of the world. Thanks

Jo
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 20, 2016, 05:11:49 PM
Back on topic:  how are you planning to attach the spokes to the rim?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 20, 2016, 11:23:08 PM
:offtopic:

Guys lets stick to discussing making our models rather than the political challenges of the world. Thanks

Jo
Sorry Jo ,it won't happen again.
Back on topic:  how are you planning to attach the spokes to the rim?
I may get the rim laser cut and turn up the profiles on my 10" faceplate. This will be a lot less work and i hope not cheating,or does laser cut bits count as "Barstock" The actuall profiles of the rim end of the spokes will be a challenge as they are quite a random shape!!,any ideas??
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 21, 2016, 01:28:49 AM
That's quite a complex rim shape. Maybe make it as two layers so you can make a socket on the inside edge to fit the spokes into?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 23, 2016, 02:33:19 PM
That's quite a complex rim shape. Maybe make it as two layers so you can make a socket on the inside edge to fit the spokes into?
Ok ,i am going down the laser cut road, this is the drawing for the rim and the other removable spokes will be added to bolt it rigidly to the faceplate. The cost of this will be 40£ cash so quite expensive, but it will keep the local economy going so that is ok and it is the first one i have ever done........I could have made it myself as i made the Hedley flywheel with no difficulties. The beeleigh flywheel is however 10" in diameter..
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 23, 2016, 05:02:39 PM
I've never had anything laser cut. How smooth and tight a tolerance do they hold? Is the cut edge square? I've been told that with waterjet the edge can be beveled a bit on thicker parts.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 23, 2016, 05:21:15 PM
I've never had anything laser cut. How smooth and tight a tolerance do they hold? Is the cut edge square? I've been told that with waterjet the edge can be beveled a bit on thicker parts.
Hi, I have to wait a week to get this back so i am also in the dark about this. As this is a seperate item to the hub the spoke ends will be adjusted to suit the final dimensions..........I will be back to Beeleigh to get more dimensions and photos on Tuesday to continue the build.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 24, 2016, 02:11:45 AM
Great the flywheel hub is done, all the rusty bolts came out easily and the Fryelux solder worked ok and actually tinned the whole surface, that gives an almost "cast" look. This seamed to have worked out really well and am quite pleased with it !! I now have to wait at least a week for the rim to be lasered so will start on the Eccentric & strap.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 24, 2016, 02:29:30 AM
Came out great!! There are a lot of little parts in that hub.  :ThumbsUp:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on June 24, 2016, 02:30:56 AM
Hi Willy,
 That has come out real nice....keep up your excellent work!

Chris,
 Re the water cutting....I had some done a few months back, 15 mm thick, hold a square over the cut face & using feeler gauges & needing 3 hands the taper is about 0.1mm, maybe a bit less, on the 50mm about the same

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 24, 2016, 02:36:10 AM
Hi Willy,
 That has come out real nice....keep up your excellent work!

Chris,
 Re the water cutting....I had some done a few months back, 15 mm thick, hold a square over the cut face & using feeler gauges & needing 3 hands the taper is about 0.1mm, maybe a bit less, on the 50mm about the same

Cheers Kerrin
Thats pretty good, even on thick stock. Thanks for the info!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 24, 2016, 04:31:02 AM
Came out great!! There are a lot of little parts in that hub.  :ThumbsUp:
Yes 40 to be exact....not counting anything at a molecular level !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 24, 2016, 04:50:32 AM
 
Came out great!! There are a lot of little parts in that hub.  :ThumbsUp:
Yes 40 to be exact....not counting anything at a molecular level !!

 :Lol:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 26, 2016, 02:20:29 AM
The governor pulley on the crank shaft is made a simple turning job and a picture of the assembly so far.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on June 26, 2016, 01:51:56 PM
Looking very good.  :ThumbsUp:

I was very happy to see the assembly thus far. Wow.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 30, 2016, 11:33:48 PM
I have got the laser cut flywheel rim back and this will be turned up on the myford attached to the large backplate, the spokes has been left in with the central hole to position it concentrically for turning the profiles. the rim of the prototype wheel was made in three parts with a very concealed attaching method. some more pics from Beeleigh.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on June 30, 2016, 11:49:47 PM
 :lolb: :lolb:

Great last photo.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 01, 2016, 01:28:14 AM
Looks like the laser cutting came out great. I really like the picture of the model with its big brother!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on July 01, 2016, 01:58:41 AM
That's a nice King Dick Mr. Willy, not something you see very often on this side of the pond.  :lolb:

The flywheel is continuing to take shape and looking great.

Still enjoying your great work.
Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 02, 2016, 01:55:31 PM
The flywheel is turned up using the 9" faceplate on the Myford....There are 8 slots in the faceplate but 6 spokes so it is held on with just two wide clamping bars. this coupled with the central turned down centre spigot has held it securely enough to machine ok. The next job is to mill the edge protrusions to the correct width and do more filing etc after removing the "spokes'......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 03, 2016, 02:21:24 AM
The flywheel is continued with the spoke flanges milled to width. tis was milled instead of turned on the lathe as there was a lot of chatter as the lathe tool was intermittently hitting each part in turn. As The slot is of a square nature being a casting this could not be milled as the tool always leaves a round corner. What i will do is mill both sides of the flanges down to the spoke thickness ,then saw and file out the slot and then solder a piece at the back to compleat the correct thickness to bolt the spoke too.......Hope this is clear..........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 03, 2016, 02:25:07 AM
Looking great!  Those spoke end fittings are quite ornate, this is going to be a very nice looking engine.

 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 05, 2016, 01:35:37 AM
The flywheel rim flanges have been milled to thickness and then sawn from the  "spokes" The hub spokes and rim have now to be connected. I shall have to make a jig to get everything concentric and level...........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 06, 2016, 02:51:35 AM
The rim flanges have been filed out square and the rear parts are soldered in place with soft solder and this was found to be strong enough for the parts to be filed to the existing profile of the flanges. A trial spoke has been filed up and slotted in place.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 06, 2016, 02:59:34 AM
Nice!!

 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 07, 2016, 01:38:57 AM
All the rear flange plates have been fitted and the assembly jig made. the first spoke has been fitted but more filling to profile it and of course the moulding webs.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 08, 2016, 02:35:56 AM
The spokes has been fitted and attached to the rim and hub. The next job is to make all the webs with their mouldings, and attach them to the spokes.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 08, 2016, 02:54:08 AM
Very nice, coming along great!  :ThumbsUp:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 08, 2016, 12:52:34 PM
Here are some pics of the engine so far ......getting there slowly.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 08, 2016, 02:31:45 PM
Last pics show what looks like work being done on the real engine? Are they restoring it? Or did you get out the wrenches when no one was looking!  :o
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 08, 2016, 05:38:51 PM
Last pics show what looks like work being done on the real engine? Are they restoring it? Or did you get out the wrenches when no one was looking!  :o
Hi, Yes they are trying to restore it but it will be a long job . the engine was built about 1830 and then in 1875 the mill burnt down and due to corn laws and things was never used again and has been out in the open for the last 120 years slowly rusting away . the engine is completet however and they are trying to restore it but everything needs approval from the heritage people !!. Every nut and bolt is also square headed so they have to make special sockets to fit them
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 09, 2016, 02:34:44 AM
The spokes ar now being filed to width....they are the same ,just a bit of shadow makes them look different....still working out how to make the spoke webs........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on July 09, 2016, 04:28:31 AM
Looking good Wille!

Lots of work so far....and way more to come! Better see if I can get  :popcorn: in bulk!

Loved the look of your model so far, as I checkin frequently one tends to forget just HOW much work you have put in to it!

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on July 09, 2016, 02:05:05 PM
Still following your outstanding fabrication work Willy and enjoying the work your doing on the flywheel. Looking great by the way........... :praise2:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 10, 2016, 01:35:11 AM
Just that bit of taper on the spokes makes a big difference in the appearance. All in the (many many) details!   :ThumbsUp:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: scc on July 10, 2016, 10:17:08 AM
Not commenting much Willy, just quietly following along and being mightily impressed.             Terry
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 10, 2016, 12:15:35 PM
Just that bit of taper on the spokes makes a big difference in the appearance. All in the (many many) details!   :ThumbsUp:
Hi, everybody ,thanks for the comments and stuff, The tapered spokes also have the cavetto moulding detail slightly tapered so when i mill those there will have to be a slight bit of offset as well ,that is halved of course. The hub end of the spoke is  .312" and the rim end is .25" over about 2.5" so the taper is ......................... and then halved to ................The last lesson in maths i had was 50 years ago so i need to do a bit of trial and error or consult my maths friend. I have a lot of friends that are experts in their own fields so i can save my brain cells for other endeavours !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 14, 2016, 12:00:20 AM
More work on the spoke web parts........ The webs for the spokes are drawn out and the dimensions sorted and reduced to 1/16th. The webs are made from 3/16 square brass stock and are milled out using an end mill and a 1/16 ball end cutters. the stock is soldered to a piece of 1/8" x1/2" brass backing piece and then screwed to a 1/4" part. This is done so the part being milled can be positioned in the vice using the vice as the reference and does not move sideways whilst being milled. the part is then desoldered after the curve on the top is filed to shape with a bit of taper on the bottom part to match the spoke taper........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 20, 2016, 01:57:25 AM
The webs have all been made for the backs of the spokes... The front mouldings will be next....... am not spending much time in the WKSP as we are having a heat wave at the moment,so am spending time in the sun........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 20, 2016, 02:19:48 AM
Looking great!
 :popcorn:

And I agree about the weather, gotta take advantage of it when you can.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 21, 2016, 01:34:59 AM
The front spoke webs are next to be made and this is more complicated than the rear ones with the odd shaped part on the rim. the hub parts have two circular pieces with the strait parts mitred in ...all 12 of them that have to match each other..
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 21, 2016, 11:54:19 PM
so a start has been made to see how it will all fit together at the hub end.......I may make the rim end detail from boxwood or maple as this will be easy to carve out by hand as per the original wooden pattern......once it is painted up it will look ok.........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on July 22, 2016, 12:05:15 AM
Willy love all the detail work mate. You continue to impress us all........... :praise2:


Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on July 22, 2016, 07:41:13 PM
fantastic work as always!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 24, 2016, 01:02:50 AM
I have made one of the front spoke webs and soldered it in place and made the square headed bolts, these are standard 10BA hex bolts with the heads filed square an attempt has been made with the rim end detail using my Grobert and Valorbe files but more work needs to be done with these......only five more to now..........Also found an article about going metric from 1863 in the Engineer magazine......it only took 100 years to happen ,sort of !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 25, 2016, 11:40:22 PM
I have had a new attempt at the spoke end parts, I have milled out the parts as a set of six and then cut them out and filed to shape using the special files from my grobert and valorbe collection The spoke ends have an inside curve on the cavetto part of the moulding which is quite tricky to reproduce. Now i am reasonably happy with flywheel i shall start on the engine proper as i hope to get it finished for the Model engineers day at Forncet on the October meet up......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 25, 2016, 11:51:37 PM
Very nice! Amazing how many layers of mouldings there are on that engine.   :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 28, 2016, 02:35:49 AM
The eccentric has been started with the drawing and the parts turned up. The sheave is made from one piece and the outside is filed up after turning a disk to file to. the slots in the eccentric are filed out using the turning rings as a datum line. the part will be filed smooth afterwards
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 28, 2016, 02:58:31 AM
I love the design of the eccentric with the slots in it, never thought of doing that before.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 28, 2016, 03:06:10 AM
I love the design of the eccentric with the slots in it, never thought of doing that before.
I think this is quite common this side of the pond and its does save a certain amount of cast iron ....and adds to the aesthetic with the rest of the casting mouldings...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 29, 2016, 02:12:04 AM
The eccentric strap rod is made. I used some small lengths of nickel silver that i have quite a lot of in small sizes. It silver solders readily and there is no colour change on the join the eccentric is finished and i used a small keyway cutter 1/16th wide .
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 02, 2016, 01:22:45 AM
The eccentric stap rod lever is made next ..it is built up from brass and soft soldered together
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on August 02, 2016, 01:33:06 AM
Is the slot to allow for adjusting the throw on the valve?

Looking great as always!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 02, 2016, 11:56:15 AM
Is the slot to allow for adjusting the throw on the valve?

Looking great as always!
Hi, Yes ,this is the main place that does this and that is why it is of quite a massive chunk of metal...
Willy
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 03, 2016, 03:10:05 AM
I have now made the brackets that take the eccentric crossrod  from the back to the front of the standards. this is a casting with a sunken detail on it . this is made by sawing a slot across it and soldering in a piece of plate. this is filed upland the back plate attached...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 03, 2016, 03:26:03 AM
The linkage for the cross rod is turned up temporarily to see how it fits
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 04, 2016, 02:04:04 AM
The other bracket has been made ,they are handed and have been fixed to the standards to check out the length for the adjuster on the eccentric strap. also a drawing for the transfer rod bearings......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 06, 2016, 02:51:41 AM
There is now a video, this is on the  VIMEO  website, of the model so far with the flywheel turning and the beam and eccentric shaft rod operating. It is called    Beeleigh mill essex model      I shall try to put the link onto this site but will have to get someone to show me how.   The next parts will be the compound cylinder block........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 06, 2016, 01:45:20 PM
Ok I have now embedded this for you to look at..........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on August 06, 2016, 11:01:52 PM
Hi Steam Guy,
 Thanks looking great, nice to see all the parts we've been watching being made fitted up. She is going to be lovely to watch when you get her finished.
Keep up the great work!

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on August 07, 2016, 02:08:22 AM
Thanks for the video of the parts so far, looking terrific!    :popcorn:   :ThumbsUp:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Johnb on August 07, 2016, 09:57:23 AM
Thanks Willy. I may have to come up to Forncett to see this, even if you haven't got it in steam by then!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 11, 2016, 02:36:41 AM
The cylinders have been started on, this is the low pressure one that the H P hangs off. The tubes are cut out of solid bar using a Rotabroach Cutter, then bored out and the cylinder tube reamed to 7/8th". Luckily the drills and reamers are long enough to reach right through the tubes, about 3.3/4" inches. More pics......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 11, 2016, 02:41:12 AM
Thanks for the messages and i hope it will be going for Forncett, and more pics
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 11, 2016, 09:04:38 PM
More work on the engine........This engine is a Woolf compound with steam jacketed cylinders......The cylinders are inside the main casting and as the steam chests ate at the top of the engine there has to be two downpipes to get the steam to the bottom of the cylinders. This is done as i have shown and as there is not mushroom between the inner and outer castings there has to be the protuberances on the jacket part. The photos shows how i will do this with the various bar stock materials. I find that when i am doing the drawings i draw how i think i will  make it but once inside the WKSP and i look at the tools and stuff to hand i do it in a different way. The port face is a case in point as i was going to bore it out of one piece , but to get the accuracy needed to solder the bits together i chucked a piece of 1" bar in the four jaw and used the 25mm Rotabroach to make an accurate hole and the Cylinder was then turned down to fit this hole. The block was then milled to size..........Vis........I have been thinking inside the fox and have come up with some novel file handles which are quite ergonomically shaped to fit the hand.!!!......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on August 12, 2016, 12:13:46 AM
Willy I am still with my friend and enjoying your fabrication work still. I am interested in seeing this cylinder develop though....... :praise2:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on August 12, 2016, 01:33:06 AM
Wow, I continue to be amazed and impressed!

The fabrication of the cylinder assembly is going to quite a piece of work; and you are off to a great start.

I'm still following along and enjoying watching you work.  :praise2:

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 12, 2016, 02:14:45 PM
Willy I am still with my friend and enjoying your fabrication work still. I am interested in seeing this cylinder develop though....... :praise2:

Don
Hi Don and Dave, following your request, more photos of the cylinder construction......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on August 12, 2016, 03:06:08 PM
That is quite a complex shape to the cylinder assembly - looking great so far!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on August 12, 2016, 05:21:21 PM
Hi Willy, thanks for the close up of the parts. Are you going to soft solder are silver solder it, I would do the later...?

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 12, 2016, 09:04:18 PM
I was going to soft solder as there is no load on the parts and i think that there will be quite a lot of filling to do to seal the parts to stop any steam escaping. Also it will be using only about 40 psi, so won't get too hot. also more pics.........
Hi Willy, thanks for the close up of the parts. Are you going to soft solder are silver solder it, I would do the later...?

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 12, 2016, 11:28:09 PM
the LP cylinder is now soldered up with soft solder, Fryolux plus tin lead solder as a filler. It was tested of leaks and seams to be ok. the next job is the steam jacket, then the HP side the holes in the side are the exhaust ports and these line up with the two outer protuberances on the steam jacket. the middle protuberance is to make room for the cylinder down comer to go.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 14, 2016, 02:18:49 AM
More work on the LP steam jacket, the top and bottom bolting faces are made, however there is an extra piece at the back that holds the rear station for the motion bracket. Also there are the cavetto mouldings that are part of the detail. I have an idea of how to do this but it needs further thought...........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on August 14, 2016, 03:43:49 AM
Hi Wiily,
 You are making good progress. Love the photos of the orginal as the guys are working on it. Think it's been asked before but is the hope to get her back into steam or just preserve?

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on August 14, 2016, 05:10:01 AM
It's just amazing to me that disassembly of the engine is even possible with the amount of rust visible!! And not a single gas axe in sight.

That steam jacketed cylinder is a pretty great approach to the problem of cylinder condensation. Quite advanced!

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 14, 2016, 01:24:59 PM
It's just amazing to me that disassembly of the engine is even possible with the amount of rust visible!! And not a single gas axe in sight.

That steam jacketed cylinder is a pretty great approach to the problem of cylinder condensation. Quite advanced!

Pete

Hi Wiily,
 You are making good progress. Love the photos of the orginal as the guys are working on it. Think it's been asked before but is the hope to get her back into steam or just preserve?

Cheers Kerrin
Yes ,they are trying to bring it back into steam and they have a full report on the actual boiler requirements in place. This is going to take some time however. They have been using plumbers freezing spray to free the seized up bolts. As all the threads are quite course they are coming undone eventually. They do say that you can always undo a Whitworth nut and bolt because of the dimensions. The threads used on the cylinder gland are actually a square thread so you only need one nut to adjust them  Vis...The nuts on the adjusting rod for the motion brackets are 16 TPI so these are very fine indeed and to model them in 1/16 scale will be challenging.....    .0039 thou !! Thanks for the interest and i am trying to figure out the easiest to way to make the LP porting........The Condensation for the cylinder jacket is catered for with a treaded hole at the back of the casting ,but no provision is made for the actual cylinders as far as i can see ......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 15, 2016, 01:29:26 AM
I am making the LP jacket protuberances next, i have bored out a piece of 2" brass using the Rotabroach which leaves a sizeable chunk of brass to use for something else. Only a small proportion of this tube is used however, and the pieces sawn off will be used as clamps when being held in the milling machine vice. I have used the Boxford  CUD for this as the belt has broken on the Myford, The first thing i did with the Boxford  was to change the position of the saddle handle wheel to the right hand side as per the Myford as i was getting into a muddle after being used to the myford after 40 years !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 15, 2016, 04:23:42 PM
Am now machining the exhaust poet down comer part. this will take the exhaust to the condenser pipe below the cal table .the casting has two protuberances, one each side of the other bulge that is hollowed out to make room for the cylinder porting arrangement.I am having to think about how to do all this very carefully so as not to have any fresh air between the HP exhaust port connecting to the LP inlet ......I will have to solder an extra slab of brass to this part to be able to get the full curves in place..........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on August 15, 2016, 04:28:25 PM
Awesome Willy! I am really enjoy this cylinder fabrication. Nice work mate...... :ThumbsUp:


Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 16, 2016, 02:00:15 AM
Thanks for the comments Don , I am sort of enjoying it as well as i have all the tools and wherewithal to make this succeed with out to much difficulty......The down pipes part is milled and filed up and the cylinder base is made. I am taking this really slowly as i keep changing my mind about how to make the bits ....this will be silver soldered together as it will have to be machined when all the bits are joined together.The cylinder block is one large casting and it must have been quite a feat to get all the parts and porting to work out successfully.!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on August 16, 2016, 02:18:28 AM
And there I was thinking that the rest of this engine was intricate... The cylinder assembly is going to be amazing. Fantastic work!

 :popcorn:   :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on August 16, 2016, 02:44:01 AM
That cylinder is a pattern makers nightmare!! And it's huge to boot. A constant reminder of how some skills and technology has been lost....

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on August 16, 2016, 09:32:45 AM
Hi Willy,
 I'm with Chris on this one!   :popcornsmall: :popcornsmall:

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 18, 2016, 01:30:26 AM
The other parts have been made and they will be silver soldered together. I will have to make sure the ports line up and also ensure that there is enough clearance so they don't fill up with the solder. I have left more metal where the join will be as there is a port that joins up with the Hp cylinder. On the beeleigh engine there is quite a gap between the cylinder and the jacket casting and they have used some sort of filler to fill the gaps........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 19, 2016, 02:22:34 AM
more work on the cylinders i have been milling the ports and drilling the base for the securing bolts to the cyl table. i have attached parts together with screws to keep everything aligned. The HP cylinder has been started and it will be silver soldered separately. the two cylinders will then be soft soldered together.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 20, 2016, 02:05:54 AM
The LP cylinder is now silver soldered together, to make sure there was enough penetration the two parts were soldered separately then when checked the parts were all joined together. The steam jacket was milled to take the cylinder port face and it is a nice tight fit. The cylinder downcomer protrusion will now be fitted by plugging the jacket part and drilling down for a slight clearance fit. This has worked out ok and the exhaust ports are still open all the way up and into the steam chest which was checked by blowing into them. I am actually quite pleased with the outcome and now need to do the same with the HP side......Now i know this works.!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on August 20, 2016, 02:50:45 AM
Again, wow!!  Quite a complex set of parts, you are making it look easy.   :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on August 20, 2016, 06:12:41 AM
Hi Willy,
 That's looking really great! I bet it was nice to know that all the cunning planing came together!

Just taking to my Dad about this engine, as he mentioned the problems he's having pulling the steam car engine apart that he's playing with as somebody has "attacked" some of the bolts with a cold chisel which has made getting them out an issue, I remembered that you posted up about plumbers freeze that been used on the full size. Have you any info on it please, I could google but it would be nice to have some first hand knowledge of which one works.

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Spamnchips on August 20, 2016, 03:58:12 PM
If any followers of this subject want to view the Beeleigh Mill Beam Engine, the next public open days are Saturday 9th and Sunday 10th of September between 11.00 to 1600 hours. Look here for more info. http://beeleighmill.co.uk/News.html
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 21, 2016, 01:13:15 AM
Hi Willy,
 That's looking really great! I bet it was nice to know that all the cunning planing came together!

Just taking to my Dad about this engine, as he mentioned the problems he's having pulling the steam car engine apart that he's playing with as somebody has "attacked" some of the bolts with a cold chisel which has made getting them out an issue, I remembered that you posted up about plumbers freeze that been used on the full size. Have you any info on it please, I could google but it would be nice to have some first hand knowledge of which one works.

Cheers Kerrin
Hi, I was not actually there when they did this but will find out soon, cheers.....
The cylinder has been inserted in the steam jacket after the connecting ports were drilled...they will be plugged with 2BA brass screws and soldered in place with Fryolus solder paste as well as the gap around the cylinder. there does not seem to be much leakage when i blew into the exhaust ports as there is a really good fit with the steam chest . i I will be using gaskets with the cylinder and see what happens under steam !
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 25, 2016, 12:15:37 PM
I have started on the HP cylinder and have used a reamer as a cutting tool to cut the curved fit for the down pipe and the port chest......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on August 25, 2016, 01:51:40 PM
Clever use of the reamer, I wouldn't have thought of that. Much longer cut than a normal end mill bit.

 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on August 25, 2016, 09:04:03 PM
Willy that cylinder is turning into a lot of work mate, but you look like you have it all in hand. Amazing work........ :ThumbsUp:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 26, 2016, 03:50:37 AM
Willy that cylinder is turning into a lot of work mate, but you look like you have it all in hand. Amazing work........ :ThumbsUp:

Don
Hi Don ,yes it is lot of work and i hope i don't have to redo any of the parts  !! the cylinder is soft soldered and the steam jacket is carved out and silver soldered ready to mill out as per the LP cylinder assy. the next job is to join the two together exactly the right distance apart, as per the beam strap widths . They also have to be parallel in both planes so i will have to make some form of jig.....
Clever use of the reamer, I wouldn't have thought of that. Much longer cut than a normal end mill bit.
Using the reamer like that is a new idea and in use the swarf was like dust and took quite a long time to do..... some more pics..........
 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 27, 2016, 02:00:31 AM
The HP cylinder block is made and now needs attaching to LP block this will be soft soldered all together. As the steam jackets are connected this will be quite tricky and needs a bit of thinking about.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on August 27, 2016, 02:26:12 AM
If the issue is not melting apart any previous parts, can you go to an even-lower-temperature solder for this, like Tix jewelry solder? Any possibility of a screw fastener somewhere between the two? Though it doesnt look like it - lots of parts in that assembly. It is looking incredible - sure you will get it sorted out.

 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 27, 2016, 11:51:59 PM
More work in progress the exhaust port from the HP cylinder feeds to the LP cylinder steam chest and i have used a stub of copper pipe to help keep the cylinders in alignment. The cylinders are then filed to meet each other with a flat to join them together. These flats will be drilled to allow the steam to go through from the LP cal to the HP cal and then into the HP steam chest. When the flats were filed I used centered  plugs to get the correct distance between them ,to match the strap centres on the beam (quite important) !! The two copper thick wires will be used to help seal the join by creating a fillet to hold the solder in place ..i think this will work......still more plugging and the steam pipe inlet to make and also a few holes to go between the cylinder steam jackets  before i take the plunge and solder them together.........
If the issue is not melting apart any previous parts, can you go to an even-lower-temperature solder for this, like Tix jewelry solder? Any possibility of a screw fastener somewhere between the two? Though it doesnt look like it - lots of parts in that assembly. It is looking incredible - sure you will get it sorted out.

 :popcorn:
Hi, The cylinder outers are silver soldered ,so i will soft solder the pair together and hope they seal ok and then use miliput to make a nice filet
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 28, 2016, 03:10:25 AM
The cylinders are ready now to be soldered together. a Jig has been made to keep the cylinders aligned. the holes have been drilled to allow the steam to reach the HP cyl and the inlet boss has been made from a piece of the metal left over from the down pipes using the Rotabroach. I will solder this tomorrow and hope it be successful.............The copper loop will be inserted between the cylinders to provide a key for a fillet....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 29, 2016, 12:27:28 AM
The cylinder block is now soldered together....and all the ports are still open including the jacket transfer holes, and nothing else has come apart !!.... there is still lots of cleaning up to do and i shall fill the joins with Milliput to give a nice fillet. The steam chest covers are next and the valves.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on August 29, 2016, 01:11:51 AM
Awesome Willy the results speak for itself....... :praise2:


Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on August 29, 2016, 01:26:08 AM
Looking wonderful. Still following along, great build! 
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on August 29, 2016, 01:42:33 AM
Hi Willy

Can you imagine the complex cores that would be required to cast what you have just fabricated here? Wow, like Don said; amazing work!

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on August 29, 2016, 02:29:32 AM
I'm still having trouble envisioning all the ports and passages in that thing..... I understand the compound principle and the reason for the steam jacket but how they are all positioned in there, along with those removable cylinder liners, is very confusing!!   :thinking: :headscratch: :insane:

Certainly a pattern makers nightmare!!

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 29, 2016, 03:11:39 AM
I'm still having trouble envisioning all the ports and passages in that thing..... I understand the compound principle and the reason for the steam jacket but how they are all positioned in there, along with those removable cylinder liners, is very confusing!!   :thinking: :headscratch: :insane:

Certainly a pattern makers nightmare!!

Pete

Hi Pete, here are some of the drawings i has made and also the plastic maquette i made earlier, Thanks for the comments ,I am quite pleased with it myself as well actually......there is a description with lots of photos in an earlier post at the beginning of this thread.....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on August 29, 2016, 04:24:31 AM
Ah Ha said the blind man! So the main steam supply goes through the jackets, of both cylinders, before it is valved into the HP cylinder. I think.....

LP jacket first, then HP jacket, then HP cylinder, then LP cylinder, then out.  What a trip!! That thing must be blazing hot when operating....

Wow. And we think we're advanced.....

Thanks very much, Willy. Not only for explaining this but for the entire project! Wonderful stuff, just wonderful.

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 29, 2016, 02:37:15 PM
Hi, Pete,   also there are usually drain cocks on cylinders to let the condensate out from the cold cylinders, however as they are inside the jackets that would be quite to difficult to do. So after finding this hole at the lowest point of the steam jackets ,i can sumize  that they let the steam into the jacket first and let the whole lot get hot and then once everything was at operating temperature, drain off the condensate and start the engine. This would prevent the individual cylinders filling with condensate and bursting under pressure...........some pics.....I have not been able to actually see inside this engine block so can only guess at what they are like. this has been quite an interesting project and has taken quite a lot of thought since October 2014 when i first discovered this engine.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 31, 2016, 02:27:15 AM
the cylinder caps are made, quite a strait forward turning job , the gland adjusting arrangement is quite unique using two ball ended bolts with a square thread for the nuts ,possibly so only one nut is necessary......The cap bolts are not exactly equidistantly placed and this is copied on the model.....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on August 31, 2016, 02:39:02 AM
I like that gland bolt set up! It would be very quick to get the gland up the rod and work on the packing without having to remove an entire bolt.... very clever those guys.

I love your work Willy, and your dedication to doing it correctly.

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on August 31, 2016, 03:37:37 AM
Do I understand correctly that the hole in the ball end fits over the post sticking out of the side of the top of the cap, and the threaded rod goes up through the T of the gland fitting? Never seen anything like that before. In the picture of your cap, there is a pin going all the way through, that will have the center cut out?  :thinking:

Very interesting build! Have you considered documenting it all in a book? Your drawings are quite detailed.

 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on August 31, 2016, 03:58:17 AM
Yep, that's how it fits! I've seen that a couple of times (not on a steam engine!) but the eye bolt was not free to just slip off the pin. They had a washer and cotter (split) pin holding the eye to the pin.

This set up is super easy and fast!

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 31, 2016, 12:17:51 PM
 In the picture of your cap, there is a pin going all the way through, that will have the center cut out?  :

 :popcorn:
[/quote]

Very interesting build! Have you considered documenting it all in a book? Your drawings are quite detailed.

 HI, Yes the pin was drilled across the recess and the pin inserted and soldered in place then returned to the lathe and drilled out. I have thought about writing something up for one of the magazines possibly Engineering in Miniature but that will be in the future.........Willbert
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on August 31, 2016, 04:48:00 PM
Beautiful results Willy, I just love all your fabrication work. You layed them out in great details and thanks for all your efforts....... :praise2:


Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 02, 2016, 02:02:00 AM
The piston rod gland bolts are fitted but will need cleaning up at a later date.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on September 02, 2016, 02:18:58 AM
Every time I look I see more little details, really like the looks of the gland bolts. The head bolts on the seam are interesting too. Very nice work!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 03, 2016, 02:10:00 AM
Have started on the steam chest. it is made from 4 pieces that will be silver soldered together, these parts are getting quite small with the valve and gland fittings ,a bit like watch making, so i hope everything will work out...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 04, 2016, 11:41:18 AM
The steam chest cover is soldered together after changing some of the parts. I found some more photos of it from a sideways angle and it was different .Putting all the valve gear train together is going to be very fiddly and difficult ,but will see what happens !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: sco on September 04, 2016, 12:01:49 PM
You seem master of any challenge Willy so no doubts here.

Will you be bringing the engine to Forncett?

Simon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 04, 2016, 01:59:58 PM
You seem master of any challenge Willy so no doubts here.

Will you be bringing the engine to Forncett?

Simon.
Hi Simon, yes i will be bringing the engine to Forncett, together with the finished  Hedley and the Bridewell engines.... Will be good to see you there........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 05, 2016, 01:20:56 AM
Starting on the HP steam chest cover. I think the shape dictates that the main steam valve is tapered. as i cannot see inside this casting it is all guesswork the 4 spoke wheel is the main valve and the smaller rod is connected to the governor. weather there are two parts to the valve inside i don't know but will do some more drawings, as these were done in October 2014 !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 07, 2016, 02:02:37 AM
Have started on the HP steam valve, a reamer was made at 4 degrees taper and the shaft is stainless steel it will be cut to length later. at the mo it has  flats filed on it to test it. The porting has been figured out as it has to miss the valve cavity...... I did try a blowing test but the cylinders and everything have to be finished and sealed for that to work.....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 08, 2016, 02:01:50 AM
The HP valve has been made...and fitted and the rear motion stantion support lug soldered in place....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on September 08, 2016, 02:10:50 AM
More stunning work!   :ThumbsUp:

What is the round hole in the side of the large cylinder for, shows in the first picture? Has a fitting on the outside it looks like too. Looking at the pics some more, looks like two holes inside the smaller cylinder too?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 08, 2016, 02:39:10 AM
More stunning work!   :ThumbsUp:

What is the round hole in the side of the large cylinder for, shows in the first picture? Has a fitting on the outside it looks like too. Looking at the pics some more, looks like two holes inside the smaller cylinder too?
hi, yes the hole in the LP cinder jacket is the main steam inlet pipe connection, and the other holes between the cylinders feed the steam to the HP steam chest. a couple of pics that show this. Thanks for the comment and there is still lots to do,,,,,,,
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on September 08, 2016, 02:50:32 AM
Ah - got it - I forgot that the cylinder goes inside, and that I was looking at the outer jacket. Quite a complex machine!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 09, 2016, 03:47:47 AM
the LP valve is started ..i use a piece of rectangular bar oversize and mark it out on the end and mill the cavity to size. The waste is sawn off after using a knife type needle fillet start the blade in the right place. They part is then filed to shape using the length of it to hold it firmly in the viice. The stock is place lower in the vice and the side is used as a stop with a hand safe edged file to keep it aligned. more later......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 10, 2016, 12:59:37 PM
More work on the valve gear....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 11, 2016, 02:03:30 AM
The gland fittings have been made and also some pics of how i make the square headed bolts using hex headed standard bolts,They are screwed into the thread gauge and filed to shape, then unscrewed to length and filed off. this gauge is hardened steel so it is not damaged by the file. i have found as well that the hex sockets actually turn them ok . The engine won't be finished for the model engineers day at Forncett but will be taken as work in progress.....also to show the construction that is usually hidden by the paint !! The bottom right hand bolt has been broken off on the original and by chance i managed to break off the drill on the model !! so i will have to put in a new bolt as well !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 12, 2016, 01:53:49 AM
The main steam valve has been made that's in the HP steam chest.When i drill holes in the small minidrill i hold the vice in place with a round flat magnet. the vice is then positioned in place whilst touching the drill stand rod, this completes the magnetic circuit and holds everything firmly in position.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 16, 2016, 04:02:25 PM
I have been back to Beeleigh and taken more measurements and photos ,some of them are wide angle thats gives a really good pic in the confines of the small engine room. I have found some discpencies in the measurements and have taken more measurements of the parts relationships with other parts as some parts don't have enough clearance and others too much. Also there is a new unused piston in the Swindon science museum  showing the method of construction.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 18, 2016, 12:17:12 AM
I have made the HP support web and used Milliput to fill in the joins with a smooth fillet. The LP valve rod has been made from Nickel Silver in one piece as the cotter is really tiny in this scale. i have to alter the front table profile as well,with the help of some new photos of this part to contain the valve rod.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 19, 2016, 02:27:25 AM
I have now taken the plunge and fixed the cylinders in place with the Trulock  and the ports are still open as i could poke a bit of solder through the transfer port. hopefully once the gaskets are on the cylinder heads there won't be any leakage. the Cyl table has been modified but needs tidying up and the HP valve has been filed to size, it is quite difficult to work on these small items but i file them up by holding them with the fingers on this squishy green felt stuff ,the pressure of the fingers and file stops the part moving about
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on September 19, 2016, 02:34:15 AM
Very nice Willy!

You are continuing to make great progress on this little beauty.

Dave

Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 21, 2016, 01:00:19 AM
The valve rod glands have been made and the bolts are 12 BA so quite small and fiddly. the cross stubs are made by drilling across No56 drill and then the end of the drill is silver soldered in and then the middle part is ground away with a Dremel tool and the part is soft soldered in place. The steam chest covers need to be made next then the cylinders are finished.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 22, 2016, 02:06:18 AM
I have been measuring up the valve dimensions and there seems to be a few discrepancies with the valve timing, the dimensions of the ports in the LP cylinder don't seem to correspond with the HP cylinder valve movements. any way i will have to check that out later. the nameplate has been engraved and attached with loctite. the original at Beeleigh is missing and does not have any screw holes to attach it, and the same with the engine in the Ramm brewery.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on September 22, 2016, 02:12:22 AM
Still with you Willy and enjoying your work........ :praise2:


Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 23, 2016, 03:15:33 AM
The valve shaft bearings are begun and they are cut from a piece of 1/4" thick angle. This is first milled to give square datum edges for marking out. As it is angle iron there is ample space to clamp it for drilling etc....It is Forncett model engineers day next week end and i will be there with the Bridewell and Hedley engines as well as the Beeleigh
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on September 23, 2016, 10:01:05 PM
looks like your making great progress there  :ThumbsUp:

is that a square headed bolt on one side and a hex head the other??
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 24, 2016, 01:38:13 AM
looks like your making great progress there  :ThumbsUp:

is that a square headed bolt on one side and a hex head the other??
Hi Bertie, they will all be square headed bolts eventually as per the original when i get round to making them all, they start out hexagon and the heads are filed square afterwards, Are you coming to the Forncett steam up on the 2nd October ? This is the model engineers day!! 

The other bearing its made and here are a series of photos showing the construction Fairley basic stuff using files and drills, the round bolting rods are soft soldered in place using Fryolux soft solder paste with a dab of cored solder as well.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on September 24, 2016, 09:00:16 PM
i ment on the original, must be a trick of the light as one looks to be a hex.

im hoping to get over to forncett on the 2nd
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 27, 2016, 08:33:21 PM
i ment on the original, must be a trick of the light as one looks to be a hex.

im hoping to get over to forncett on the 2nd
Will be good to meet you at Forncett, and this engine is almost 200 years old so i suppose a lot of the original nuts /bolts may have been changed. I have made a temporary base/stand for the Beeleigh engine to make it a bit more presentable for the Model Engineers day at Forncett. I have also been to the Science museum and looked at this Woolf compound engine, that is on the TO DO list !! but will need to finish the currant one first !.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 30, 2016, 12:33:50 AM
A bit more work on the valve gear, the adjusters on the bottom of the valve rods are made
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on September 30, 2016, 12:40:15 AM
Really looking great! The base really sets the engine off well.   :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 01, 2016, 02:01:41 AM
Really looking great! The base really sets the engine off well.   :popcorn:
hi, this base is just a temporary one made from MDF and dolls house brick wallpaper to display at the local Forncett museum Model engineers day this Sunday. I shall take lots of pics to show some of the engines from the local MEM members.
The main steam valve handle is made and the condenser adjustment box housing is fitted.........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 02, 2016, 12:10:25 AM
The steam chest cover is made for the HP cyl, First a strip of brass is turned to thickness, the turning marks are filed off and then the plate is sawn off,filed to profile and bolted in place......Forncett tomorrow and then preparing for the autumn and winter at the allotment !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bertie_Bassett on October 02, 2016, 09:17:03 PM
and it even looks good in the flesh!

(http://i655.photobucket.com/albums/uu280/b-bassett/DSC_1251_zpsmjj6piat.jpg) (http://s655.photobucket.com/user/b-bassett/media/DSC_1251_zpsmjj6piat.jpg.html)
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on October 03, 2016, 12:33:43 AM
Hey! good to see it out in public.

I'm still here following along with your work; as you continue to make great progress.

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 04, 2016, 07:11:59 PM
and it even looks good in the flesh!

(http://i655.photobucket.com/albums/uu280/b-bassett/DSC_1251_zpsmjj6piat.jpg) (http://s655.photobucket.com/user/b-bassett/media/DSC_1251_zpsmjj6piat.jpg.html)
Hi, thanks for the photo......i will be posting more pics from the exhibition soon
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 05, 2016, 01:24:52 PM
More photos of the Forncett  Steam museum Model engineers day   2nd October 2016........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on October 05, 2016, 05:48:02 PM
Some great looking models there! Thanks for sharing them.

I was wondering about the one with the 'feet' on the drive wheels, looks like a rotary duck walker. Was that a real vehicle? It also has a great companion piece behind it on the right, a 'model tree' - great idea!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on October 05, 2016, 07:59:10 PM
Beautiful engines Willy thanks for sharing them. Your engine is really looking great..... :ThumbsUp:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 06, 2016, 01:47:15 AM
Some great looking models there! Thanks for sharing them.

I was wondering about the one with the 'feet' on the drive wheels, looks like a rotary duck walker. Was that a real vehicle? It also has a great companion piece behind it on the right, a 'model tree' - great idea!
Yes ,this is a Burrell of Thetford traction engine and the date on the drawings is  AD 1855 Nov 27   !! a few more pics as well......These are antique engines from the collection of R.O. Clark a local historian and writer of Steam engine collections in East Anglia.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on October 06, 2016, 01:51:58 AM
Those are beautiful engines, thanks for the pictures!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 08, 2016, 12:58:58 AM
I have now made a trial set up for the valve events and the dimensions work out, so now have to work back to the eccentric
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on October 08, 2016, 02:05:38 AM
Very clever way they did the valve lifters, have not seen that type before. This engine just keeps getting more interesting!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 08, 2016, 03:07:26 AM
Very clever way they did the valve lifters, have not seen that type before. This engine just keeps getting more interesting!
Yes  quite clever and they only need one valve rod instead of an up and over type. they then need this push part so the rod does not bend.Here is a picture of the Bridewell engine showing the up and over push rod type. You can also remove the steam chest covers to make adjustments easier as well i think. these early engine makers were quite cunning in using as little metal as possible !!........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: IanR on October 08, 2016, 11:52:03 PM
Some great looking models there! Thanks for sharing them.

I was wondering about the one with the 'feet' on the drive wheels, looks like a rotary duck walker. Was that a real vehicle? It also has a great companion piece behind it on the right, a 'model tree' - great idea!
Yes ,this is a Burrell of Thetford traction engine and the date on the drawings is  AD 1855 Nov 27   !! a few more pics as well......These are antique engines from the collection of R.O. Clark a local historian and writer of Steam engine collections in East Anglia.
H O Clark was the collector of these engines, his son R H Clark was the writer, and R O Clarke was a motorbike shop in Norwich.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 10, 2016, 01:27:02 AM

H O Clark was the collector of these engines, his son R H Clark was the writer, and R O Clarke was a motorbike shop in Norwich.

Hi, thanks for that, I should have known that as R.O.Clark motorbike shop was just down the road from where i live with Chapmans  shop.
I have started on the ball joint valve links and  these are made like this as there is a small amount of movement in both planes. They are made with two pieces of square brass drilled with a round nose milling cutter to the correct depth for the ball that will be silver soldered to the arms. the two parts are bolted together using the ball to align them prior to soft soldering to a stout piece of copper faced printed circuit board. bolted to the  faceplate. I have not tried this before so will see what happens. I have used a piece of this board as it will not be so heat conducting as solid copper to enable easier and quicker soldering together.,,,more tomorrow
n
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 11, 2016, 02:49:26 AM
The part is soldered onto the facedplate PC board with the 250 watt soldering iron. The part is first centred using the tailstock, then turned to dimension. The part is then desoldered and turned over after drilling a hole so the part can sit flush on the board. the part is then desoldered again and sawn and filed to shape. still a bit more cleaning up but it has worked out OK.....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 12, 2016, 11:58:45 PM
Have made the arm for the ball joint, I have silver soldered a 1/8th steel ball to the end of a square shaft and filed to shape another one to do then all the linkages are made. Good to see Tug tonight talking about his steam engine boat at the model engineers meeting in Norwich......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on October 13, 2016, 01:27:36 AM
Some beautiful fabrication on those links.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 15, 2016, 12:58:49 AM
the top linkage has been made and connected to the valve shafts.   there is more adjusting to do though.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 15, 2016, 02:46:47 AM
Quote from: crueby
Some beautiful fabrication on those links.
[/quote

Thanks for the comments, however they should be a bit better and will be worked on before painting. I am being filmed in 2 weeks by the Essex film maker group who are documenting the restoration of the mill at Beeleigh so i shall be saving some of the work for them to film. The restoration will be quite a lengthy undertaking so any footage will not be available for some time!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Admiral_dk on October 15, 2016, 12:21:42 PM
I will be filing the use of PCB cut-offs away for future use - nice idea.

Thank you for documenting your interesting project.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 19, 2016, 12:53:49 PM
I will have 3 of my models engines at the Lowmax exhibition this weekend...The Bridewell beam engine, The Headley beam engine and the A.M.Oscillating engine. I won't be there in person but there will be members from the Norwich sosciety  in attendance.........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 26, 2016, 02:55:46 AM
The valve gear has been made but it is quite a tight fit trying to get everything in the right place and to adjust everything in situ. It is also very difficult on the big engine as well getting in to measure everything, I will have to make the bearings on the standards again as they are slightly to long. It is a good idea to measure the distances between all the components, as well as the parts themselves.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 01, 2016, 12:48:46 AM
I have finished the valve gear and it has been posted on VIMEO the link is      Valve events Beeliegh Mill   I will try to post it on this site but so far have not been able to. I have not got much done over the last 2 months as i live in a council house and have had my 5 year inspection and have been told i am a hoarder and have to "clear" the property. so i have had 3 more inspections and it is still not good enough as they have a duty of care to not let me hurt myself....rhubarb rhubarb rhubarb.........................anyway the motion work is next on the list
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on November 01, 2016, 01:56:36 AM
I have finished the valve gear and it has been posted on VIMEO the link is      Valve events Beeliegh Mill   I will try to post it on this site but so far have not been able to. I have not got much done over the last 2 months as i live in a council house and have had my 5 year inspection and have been told i am a hoarder and have to "clear" the property. so i have had 3 more inspections and it is still not good enough as they have a duty of care to not let me hurt myself....rhubarb rhubarb rhubarb.........................anyway the motion work is next on the list

Well, if the problem is too many steam engine models, you can send the  here!   :Lol:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 01, 2016, 02:35:23 PM



Well, if the problem is too many steam engine models, you can send the  here!   :Lol:
[/quote]
Thanks, i'll let6 the council know !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 01, 2016, 05:20:57 PM
Here is the vid of the valve events



<iframe src="https://player.vimeo.com/video/189639278" width="640" height="360" frameborder="0" webkitallowfullscreen mozallowfullscreen allowfullscreen></iframe>
<p><a href="
">Valve events Beeliegh Mill</a> from <a href="https://vimeo.com/user44309902">robert Bailey</a> on <a href="https://vimeo.com">Vimeo</a>.</p>
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on November 01, 2016, 06:59:06 PM
That is a wonderful machine to watch all the movements going! Such beautiful work...

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on November 01, 2016, 09:48:38 PM
That is looking terrific! Thanks for the video of the valves - its going to be a fun one to watch under power.
 :ThumbsUp: :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on November 01, 2016, 10:18:46 PM
Just awesome Willy, and love the motions........ :praise2:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 05, 2016, 01:18:16 AM
Thanks for the comments, I'm also quite pleased and impressed !! Started on the motion work with a mock up of the pistons ,rods ,crossheads and straps. All the motion rods will have to be made for the movements to work smoothly though....
and still "clearing the property" as per orders from the council inspector  :( :( :(
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on November 05, 2016, 03:31:29 AM
Hi Willy,
 Still following along & really like the action so far of the motion works, it's going to be memorizing when you finally get it all done.
 Bloody council workers, don't they know that this work in progress is far more important than reducing important storage for future projects  :lolb: I hope you are being very selective on what you are moving!

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 05, 2016, 11:39:14 PM
Hi Willy,
 Still following along & really like the action so far of the motion works, it's going to be memorizing when you finally get it all done.
 Bloody council workers, don't they know that this work in progress is far more important than reducing important storage for future projects  :lolb: I hope you are being very selective on what you are moving!

Cheers Kerrin

Hi Kerrin.....yes i am trying to get things to the people that will really appreciate the stuff.......I have made a few more parts ,namely the reach rods ,and have found that the Watt  parallel motion seams to work ok without the radius rods in place !! so the radius rods stanchions and support rods needs to be made next then a steam test can be done........ :ThumbsUp:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 15, 2016, 03:36:24 PM
Back to work again after a short holiday in London and then nursing my pulled back muscles.....The motion support stanchions are made and the end stretcher is made using a built up part. the support stanchions fit into rounded parts that are annealed ball bearings ,drilled and silver solder onto the cross rod. This rod has the rear profusion that is a flat piece of stock drilled and soldered in place before filing to shape. The balls are annealed by heating to red hot for a time and then left to cool slowly by putting the back hearth piece over the top of the balls so they take longer to cool down........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 16, 2016, 01:13:22 AM
The motion support bracket is continued by making the back part, this is made by drilling a hole in a piece of steel that the shaft will go through to keep everything in alignment. the balls have been drilled and the whole lot soldered together. Once soldered it is filed to shape and attached to the engine casting.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on November 16, 2016, 01:59:59 AM
Looking great!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on November 17, 2016, 03:58:42 PM
Still with you Willy and looking at some outstanding work. You know .......I........like......../ :Love:


 :popcorn:
Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 18, 2016, 02:42:04 AM
Thanks Don, and i am now ready to try out the engine under steam. The dummy motion work is completed and the correct items will be made using the dimensions from the dummy ones. Not everything lines up exactly so there will need to be some creative fitting and adjustments made. So i have to make some gaskets and the LP steam chest cover, also lots of odd bolting down items to keep everything stable and sturdy......... This means taking everything apart and hoping it will go back in the same place ...........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on November 18, 2016, 03:10:44 AM
Great to see the motion links all in place, the shape of that center part makes sense now. Best of luck on it's first steaming!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 20, 2016, 02:32:34 AM
Good to see MEM back on line. Here is the engine with most of the upstairs parts in place to see what it looks like. the motion straps and parts will be made correctly once the steam test,( to check the engine and valve gear works ok) ,is working. The underneath parts ,air pump and condenser also need to be made.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on November 20, 2016, 04:45:12 AM
That is looking wonderful - it is a very graceful design!

In the restoration of the real engine, do you know if they will actually be steaming it again? At least turning it with a motor or something to show the motion, I hope.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 21, 2016, 01:03:34 AM
That is looking wonderful - it is a very graceful design!

In the restoration of the real engine, do you know if they will actually be steaming it again? At least turning it with a motor or something to show the motion, I hope.

Yes they have the plans for a new boiler drawn up for it . but it will be a completely new set up rather than using the old elephant boiler that is already there. There is not enough room for an electric motor, and they have not been able to disconnect it from the hurst (the corn milling machinery) yet either.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on November 21, 2016, 02:13:34 AM
Thanks for the pictures of the boiler area - interesting!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 22, 2016, 07:54:08 PM
The steam chest covers are made, however the HP side does not have the whole surface area bolted to the steam chest like the LP side.....nearly ready for the steam test..................
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 26, 2016, 04:42:51 AM
Getting ready for the steam test. I have put gaskets and steam seal on the cylinder caps. i tried to put graphited yarn on the pistons but it did not seam to work, i will put it in the glands later though. I have had to adjust various parts with wedges and some nifty fitting. I will also have to make a steam connection pipe. when it is steamed up the steam is admitted to the jacket and allowed to heat up the whole cylinder block to working temperature. this is because there are no drain cocks on the cylinders them selves. Once the cyl block is up to temperature the condensate is drained off with more steam at the lowest point at the back of the LP side. So a drain cock will also have be made.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on November 26, 2016, 04:55:25 AM
Always exciting to see it go the first time - and always one more little thing to get done first. Looking forward to it!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on November 26, 2016, 07:40:20 AM
Looking good Willy. Looks like the happy dance isn't to far away now!

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 29, 2016, 11:57:11 PM
Ok ,so i have done as much as i can for the steam test to try out with the steam valves attached the lower one to release the condensate........and .......am a bit hesitant to do it ,as usual , I am hoping the Loctite 638 will hold up as well as the steamseal compound. now i know what Woolf was feeling with quite a few onlookers gathered around !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on November 30, 2016, 02:31:07 AM
Don't worry, we are not looking... well, yes, we are, but we are a very sympathetic crowd!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 03, 2016, 03:15:00 AM
Ok so i have tried a steam test but no luck yet...... i had a few leaks on the glands as the graphited yarn was quite tricky to put in on this small size. What i did was to use some ordinary cotton yarn and ran it over a graphite carpenters pencil. this was a lot easier to install. I tried the steam test but nothing happened even at 40 lbs so i will have to take it all apart and go through everything. I think it may be the steam getting to the HP steam chest via the HP valve chest stop valve...the four handled valve..
The steam is heating up the steam jacket ok and the drain valve works ok.......so back to the drawing board.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: sco on December 03, 2016, 08:54:26 AM
Keep at it Willy - we know you've got the know-how to sort it.

Simon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 06, 2016, 10:51:36 PM
ok ,so i have found a couple of leaks and weeps, and have removed the cylinder from the jacket by screwing a long bolt in the bottom of the casting. I used Bakers fluid with soft solder as this is quite corrosive and penetrative and it seems to have worked so i need to reassemble everything again and have another go.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 08, 2016, 01:40:58 AM
The cylinder has been soldered and i have also used J D Weld to doubly seal it. the cylinder with piston has been polished up using brass and oil by reciprocating the piston rod for about 5 mins. The cylinder has been refitted using the Trulock 742 Gasket eliminator...there is also a short video on Vimeo with the piston breath test.!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 08, 2016, 04:18:06 AM
The LP cylinder breath test even with my asthma !!

Beeleigh Mill beam engine breath test
Anyone
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on December 08, 2016, 04:23:43 AM
Thats excellent! Now we just need to heat you up a bit more so you breath out steam...!

Watching along, looking great!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 08, 2016, 04:40:22 AM
Thats excellent! Now we just need to heat you up a bit more so you breath out steam...!

Watching along, looking great!

Thanks for the comment....funny how it goes in when i blow and out when i suck !!! oh well back to the drawing board !!....................
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 10, 2016, 05:07:26 PM

P1100191
Only me
 
There is still a leak in the cylinder that i found when i reassembled the cylinder block, so i took it apart and did a pressure water test and discovered a pin hole that will need sorting out. I should have done this before but as the breath test worked i thought it was ok......I will have to use more JDWeld as i cannot reheat it and use soft solder......Sorry i am a bit late with the text but i was at a talk on mass consumerism ............
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 11, 2016, 02:04:47 PM
Fun at Norwich model engineers today    Santas special train rides.......Elf's and safety in evidence.........

P1100202
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 14, 2016, 03:10:34 AM
I have been doing more work for the next steam test. I have stopped up the pin hole with J D Weld and that seems to have worked......i have also been fitting 1/64" gaskets and flatting the mating surfaces. I have had to refit the valves as the 1/64" gaskets equates to 1/4" in the full size. All the bolts on the big engine are square headed and are used without washers and mine will be changed at a later date
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 18, 2016, 01:56:26 AM
the steam test again

P1100226
Only me
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 18, 2016, 02:03:51 AM
The steam test was successful untill the plastic pipe broke !! I had to change the valve to get the pressure on the port face because the gaskets 1/64" left too much gap This 1/64" equates to 1/4" on the full size engine. The slot in the valve was filled with J B Weld, then filed to make a good fit. The electrically fired boiler makes it quick and easy to produce the steam up to 80 Lbs per square" Cant put any photos on this post at the moment but will try later !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on December 18, 2016, 02:16:21 AM
Glad to see it is moving forward, that is quite a complex engine!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on December 18, 2016, 02:34:31 AM
The steam test was successful untill the plastic pipe broke !! I had to change the valve to get the pressure on the port face because the gaskets 1/16" left too much gap This 1/16 equates to 1/4" on the full size engine. The slot in the valve was filled with J B Weld, then filed to make a good fit. The electrically fired boiler makes it quick and easy to produce the steam up to 80 Lbs per square" Cant put any photos on this post at the moment but will try later !!

No plastic steam lines!!!!.... 8-)
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 18, 2016, 03:35:30 PM
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Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: fumopuc on December 18, 2016, 03:39:01 PM
... a couple of minutes ago I  have got a "Forbidden" also and could not get in at all.
So don´t worry, it is all random.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 18, 2016, 04:43:33 PM
Photos.....and new bit of 20 bar pipe!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 18, 2016, 05:19:35 PM
[quote author=crueby
Glad to see it is moving forward, that is quite a complex engine!

Of course in 1825 it was the equivalent of rocket science !! except they didn't call it that !!  I wonder what they did call it back then !! any suggestions ??
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on December 18, 2016, 04:22:31 PM
Glad to see it is moving forward, that is quite a complex engine!

Of course in 1825 it was the equivalent of rocket science !! except they didn't call it that !!  I wonder what they did call it back then !! any suggestions ??
Hmmm... Loco Science, Steam Science, Magic, Alchemy? Thats a good question!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: kvom on December 18, 2016, 06:39:45 PM
If it was actually built in the 1820s it was one of the very first compound engines.  Arthur Woolf apparently was the inventor of compound high pressure steam engines about that time.  So I propose Woolf science.

Assuming that the engine at Maldon is a Wentworth, then they were building Woolf compound engines at least as early as 1835.

One website I visited says the engine was build in 1845.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 18, 2016, 08:25:45 PM
Great its all sort of working

Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on December 18, 2016, 08:43:15 PM
Hey Willy,

8mm 20 bar air line.    but what is it rated at steam pressure?    150 psi steam is approximately 370 degrees F.   I suspect that hose will turn into a balloon and burst from the heat probably at something far below that pressure because of the temperature.

Standard copper will work much better.

Just be safe.

Dave   
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on December 18, 2016, 07:39:45 PM
The test looked great!

That was just the high pressure cylinder?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 19, 2016, 03:20:28 AM
[quote author=crueby
The test looked great!

That was just the high pressure cylinder?
Hi it was just the LP cylinder in fact as i have left out the HP valve to let the steam go through the HP exhaust port into the LP steam chest. I need to J  B Weld the HP valve  as i have done with the LP valve......so lots more "fitting" to do..............When i have adjusted the HP valve i can reconnect everything and put the engine back on the bed and trying it again under steam .....Thanks for the interest

Willy
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on December 19, 2016, 01:24:57 AM
[quote author=crueby
The test looked great!

That was just the high pressure cylinder?
Hi it was just the LP cylinder in fact as i have left out the HP valve to let the steam go through the HP exhaust port into the LP steam chest. I need to J  B Weld the HP valve  as i have done with the LP valve......so lots more "fitting" to do..............When i have adjusted the HP valve i can reconnect everything and put the engine back on the bed and trying it again under steam .....Thanks for the interest

Willy
Its all very interesting - I know the general theory of the compound engines, but never seen one go together before.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 19, 2016, 04:42:41 AM

Quote from: crueby

Its all very interesting - I know the general theory of the compound engines, but never seen one go together before.
[/quote

Hi This is the maquette i made to work out the internals in Perspex. The green is the inlet ports and the red is the exhaust transfer port from the HP to the LP steam chest. the exhaust 'orange' from the LP cylinder then goes down both sides of the casting to the condenser. This engine has everything tucked away out of sight which makes for a very neat and unclutered engine block. A lot of the later compound engines look quite clumsy with all the external pipes and things, rather like an old fashioned 20's engine compared to a modern "blown" type that comleatly  fills the engine compartment.I have also used a different piece of reinforced clear hose rather than the black/yellow hose that works ok....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on December 19, 2016, 11:25:16 AM
Willy if you're interested in the math of it, go to the back half of this presentation

http://www.neme-s.org/The%20Construction%20of%20the%20Steamlaunch.pdf

There is a dissertation on the pressure volume diagram for a cross compound, ( cranks at 90 degrees), but I also have the math for a Woolf compound as well.

The Woolf compound is actually simpler because  there is no need for a receiver between the HP and the LP.

I can find this book online if you like.

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on December 19, 2016, 11:27:51 AM
PV diagram for a 2HP cross compound.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 19, 2016, 01:32:03 PM
[quote author=steamer link
PV diagram for a 2HP cross compound.

Thanks for that i will get my Mathematician friend to help me go through it and explain it to me.......
Willy...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on December 21, 2016, 01:51:24 AM
Hey Willy,

Listen, I've been around steam all my life....it's a wonderful Terrible thing....it's amazing how much power and beauty it possess.

It also amazing how badly it can hurt you.    Braided poly water line isn't steam rated..even at 30 psi from that little pot boiler, it's going to hurt you.

I'm sure you have far more experience than others, but that can be problem for the newbe who doesn't know any better...

What's worse...is making it safe in the first place isn't any more difficult.    At the least..with 30psi max..put some silicone line on, such as is used on the Midwest boiler kits readily available at the hobby shops.   it's sold as fuel line and will stand up to the temperature much better

Better still, put some copper tube in.    It's not that much of a imposition, and it sets the proper example on a forum that condones safety first.

I leave that to you.

steamer

Moderator.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 21, 2016, 02:06:19 AM
Hey Willy,

Listen, I've been around steam all my life....it's a wonderful Terrible thing....it's amazing how much power and beauty it possess.

It also amazing how badly it can hurt you.    Braided poly water line isn't steam rated..even at 30 psi from that little pot boiler, it's going to hurt you.

I'm sure you have far more experience than others, but that can be problem for the newbe who doesn't know any better...

What's worse...is making it safe in the first place isn't any more difficult.    At the least..with 30psi max..put some silicone line on, such as is used on the Midwest boiler kits readily available at the hobby shops.   it's sold as fuel line and will stand up to the temperature much better

Better still, put some copper tube in.    It's not that much of a imposition, and it sets the proper example on a forum that condones safety first.

I leave that to you.

steamer

Moderator.

Thanks for that and I shall investigate alternative types of hose pipe over here, it was a temporary job that i bought on sunday when all the other shops were closed. I know this is no excuse and shall bear the safety aspects in mind in future.

I have had to make a new eccentric stub as the original one did not have a enough "throw". after measuring the amount of travel needed from the links already made i turned up a new one. I also left a stub on the side of it that has an adjustment screw on it to position it correctly. this will be removed before final assembly. Also when i was turning the rear portion I needed to return the sideways movement away from the chuck, and this was accomplished by resting a heavy piece of steel on the bed and clamping the tailstock in the correct position. I have not seen this before and think it could also be used as a form of indexing with different thicknesses of stock just dropped in place.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Jo on December 21, 2016, 09:27:59 AM
Thanks for that and I shall investigate alternative types of hose pipe over here, it was a temporary job that i bought on sunday when all the other shops were closed. I know this is no excuse and shall bear the safety aspects in mind in future.

"Hose pipe" is not safe for transferring steam:
Flexible high pressure/temperature couplings suitable for pressurised steam are a highly specialised and expensive item that will not be common to come by - you will have to go to an industrial supplier. In contrast (non seamed) copper tube is easy to come by, cheap and suitable for transferring high pressure super heated steam. Do not use water pipe for steam pipe :hellno: it is not designed to transfer the high temperature and pressures found in steam applications.

Remember: When we test a boiler for safety not only the boiler is pressured tested but also all of its fittings and steam pipes. This not only for your safety but also for the safety of those you love and everyone else. Treat steam with respect - it doesn't care what it does to you.

Jo


Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on December 21, 2016, 03:23:37 PM
Suppliers like these guys do have hose that is meant for steam use, at least at the pressures that the G guage live steam locos use. Pricey for long lengths, but usually we only need a short piece.

http://www.thetraindepartment.com/live-steam-parts-accessories/hose-and-tubing/

This place is in US, sure there must be UK equivalents.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Jo on December 21, 2016, 03:53:10 PM
Suppliers like these guys do have hose that is meant for steam use, at least at the pressures that the G guage live steam locos use. Pricey for long lengths, but usually we only need a short piece.

Yep: STEAM HOSE: Reinforced EPDM Rubber with high strength Nylon piles. Standard safety factor 10:1. Notice that those guys also do special steam hose couplings to safely hold it in place. If you want to go to a higher pressure then that type of steam hose has steel reinforcing 8)

Jo
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 21, 2016, 05:47:34 PM
Thanks for that and I shall investigate alternative types of hose pipe over here, it was a temporary job that i bought on sunday when all the other shops were closed. I know this is no excuse and shall bear the safety aspects in mind in future.

"Hose pipe" is not safe for transferring steam:
Flexible high pressure/temperature couplings suitable for pressurised steam are a highly specialised and expensive item that will not be common to come by - you will have to go to an industrial supplier. In contrast (non seamed) copper tube is easy to come by, cheap and suitable for transferring high pressure super heated steam. Do not use water pipe for steam pipe :hellno: it is not designed to transfer the high temperature and pressures found in steam applications.
Remember: When we test a boiler for safety not only the boiler is pressured tested but also all of its fittings and steam pipes. This not only for your safety but also for the safety of those you love and everyone else. Treat steam with respect - it doesn't care what it does to you.

Jo



Hi Jo ,thanks for this i will repost this so other people will see it
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on December 21, 2016, 05:57:51 PM
OK enough said.


Willy, if you'd like, and because you seem genuinely interested in the inner workings.....I'll dig out Peabody next week, and put something together..

Can you "drive" a spreadsheet?   


Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 21, 2016, 07:17:25 PM
OK enough said.


Willy, if you'd like, and because you seem genuinely interested in the inner workings.....I'll dig out Peabody next week, and put something together..

Can you "drive" a spreadsheet?   


Dave


Ok thanks ,i can get someone to help me do that i am sure.........There is quite an interesting article on the   Stumf una-flow system in the currant issue of Engineering in Miniature at the moment, talking about Ti  & Te  etc etc
Cheers  Willy........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on December 21, 2016, 09:30:31 PM
Ahhh Uniflow...it's a bit different...but fascinating as well.

I'll dig up the pages from the book.

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 25, 2016, 12:26:03 AM
Ok so the engine is all connected up again and the motion work all adjusted to get everything turning over smoothly, I have taken note of the previous advice and now have a copper pipe connecting the engine to the boiler. I do have a supply of copper pipe ant fittings so it is quite quick and easy to connect up properly. i did another steam test but it did not work ,so will have to think about the timing adjustment. Is there a convention as to the direction of travel for the flywheel on these engines if they are not required to work in reverse mode ?? any suggestions ?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on December 25, 2016, 02:49:59 AM
Were there enough bits of the original engine still connected up to work out which way it should turn? Seems like if you offset in the same direction from the main crank pin you should be good.

Or, if it was all in a rusty pile in the corner, never mind!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 25, 2016, 02:45:50 AM
[quote author=crueby
Were there enough bits of the original engine still connected up to work out which way it should turn? Seems like if you offset in the same direction from the main crank pin you should be good.

Or, if it was all in a rusty pile in the corner, never mind!

Hi, yes it is all still connected and it looks like the crank pin and the eccentric sheave are actually in line rather than offset. The valves look as though they are at the top of their travel and the piston rods are just a bit raised from the middle position. I think the flywheel should turn into the middle of the engine to make the engine sit firmly secured down onto  the bed. anyway i shall read up on this in my books.......So these are the photos...........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on December 25, 2016, 05:34:43 AM
They are in line, but since the crankshaft goes vertical to the beam while the valve rod goes horizontal to the valve crank, there is actually a 90 degree offset. If your valve cranks are all the same orientation as the original, then the rotation direction would work out the same. Just turn the flywheel and see which direction makes the valve open at just after tdc and bdc. A little tweaking is probably needed for travel distance.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: plataman on December 25, 2016, 03:59:11 AM
What a fantastic project and huge challenge! This is a once in a lifetime opportunity to model this unique engine, I am envious and will follow your progress with great interest. Have a great holiday! Terry across the pond in Texas.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: sco on December 25, 2016, 04:38:35 AM
Still following studiously Willy.  What do you think the stepped cone was for just inside the eccentric?

Merry Christmas to you,

Simon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 25, 2016, 12:11:37 PM
Hi Sco it is for the governor but why it has 4 steps  is unusual, perhaps they were not taking any chances to have to take it all apart again !!   seasons greetings etc etc ...........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: sco on December 25, 2016, 12:37:11 PM
So the governor was belt driven - isn't that risky in that if the belt breaks the engine runs out of control or is there something that shuts the steam off if the belt breaks?

Simon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on December 25, 2016, 12:41:01 PM
Hey Willy,

Merry Christmas!     Keep that line short so it doesn't condense out all your steam.

Unless it has a reverse gear, it will only run in one direction.

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on December 25, 2016, 01:13:17 PM
You can insulate the copper with some string, just keep tying half hitches....works well

Dave

Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 25, 2016, 04:30:22 PM
     
So the governor was belt driven - isn't that risky in that if the belt breaks the engine runs out of control or is there something that shuts the steam off if the belt breaks?

Simon.

Hi Simon, this is the picture of the main steam valve and the governor connection. What is happening inside the steam chest is a bit of a mystery, but, as the governor linkage goes through the middle of the steam valve into the tapered part, and it has a handle attached it may be that if the belt does break then the inner valve will cut the steam off automatically. When the engine is started perhaps this governor linkage is held open by hand till the engine picks up speed to keep it open.........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: sco on December 25, 2016, 05:18:37 PM
OK Willy that makes sense, keep up the good work,

Best wishes,

Simon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 27, 2016, 01:35:14 PM
[quote author=plataman
What a fantastic project and huge challenge! This is a once in a lifetime opportunity to model this unique engine, I am envious and will follow your progress with great interest. Have a great holiday! Terry across the pond in Texas.

Hi Terry, yes i do feel lucky to be able to make this engine, and to clamber all over it unsupervised. They are in the process of restoring it but it has lane open to the weather since 1875 when the mill burnt down, so is completely seized up. This will be a long job for them i think!!.
I have had to make a few minor adjustments to my engine to fit all the different parts together in proper alignment. also i found another blowhole leak between the cylinder steam jackets that i have filled with J B Weld. I originally used Milliput but that was a mistake. We do have a lot of engines over here that are in various stages of restoration and decay so there is a lot more work for me to do.................
Willy.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 28, 2016, 03:27:43 PM
Ok so the J B Weld has blocked up the pinhole and all i need to do is sort out the timing and adjust all the Linkages to get the valve events correct. I have changed the eccentric sheave to get more movement on the valves and also had to slightly (actually quite a lot) eccentricate  the sweep rod pinion as the pistons were bottoming out in the cylinders !! There is hardly any room to get at the valve rod adjusting nuts on the HPcylinder side and to give an idea how small these parts are, the threaded rod is 10BA !!What i have to do is remove the cylinder block and table ,adjust them then replace them and try a steam test again, and again, and again...........I have also had to strengthen the A frames at the bottom as there was quite a lot of sideways movement from the eccentric rod causing the soft soldered fabrication to part company This should have all been silver soldered in the first place or a casting made !!..............
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on December 28, 2016, 05:50:07 PM
Willy been taking in all you pitfalls and still with you mate. Still enjoying your fabrication work..... :praise2:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on December 28, 2016, 07:29:13 PM
The part of the build where you have to disassemble/reassemble over and over is not a lot of fun, but the feeling you get when it finally goes is fantastic!

 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 29, 2016, 03:08:44 AM
[quote author=crueby
The part of the build where you have to disassemble/reassemble over and over is not a lot of fun, but the feeling you get when it finally goes is fantastic!

 :popcorn:


Hi, yes i agree with that ...so i tried the steam test again and again the LP piston went up and down ok but the HP piston just stayed up and would not push down ....so i have taken it all apart and found a pinhole in the HP cylinder, so the steam was leaking into it from the steam jacket,  the same as what happened in the LP side. this will be caulked up with J B Weld and tested properly then reassembled .......................
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 03, 2017, 10:13:31 PM
Ok at last the engine is going under its own steam !!!!!! theam condenser and air pump is not yet made and more stuffing needs to be installed in the glands. I now have to make all the proper parts for the motion work etc etc  and now am very pleased that it is now working........ :whoohoo: :cartwheel:



P1100285
Anyone
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on January 04, 2017, 12:43:20 AM
Well done Willy!

That's looking really cool!

Stuff box leak? What ..... aren't they scale as per the original? They add to the charm! I'm sure you will get them sorted in due course

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on January 04, 2017, 12:54:06 AM
Excellent!!  The smile said it all!

 :NotWorthy:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on January 04, 2017, 01:02:18 AM
Awesome Willy, yeah the smile says it all mate....../ :praise2:


Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on January 04, 2017, 02:35:05 AM
Beautiful, Willie!!  Wonderful motion that is.. can't wait to see it go with all the bits attached.. :praise2:

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on January 04, 2017, 03:03:44 AM
Nicely Done Willy!    She's a runnah!!!!


Congratulations Sir!

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: b.lindsey on January 04, 2017, 01:13:02 AM
Very nice Willy. Running them on real steam sure adds a lot too!!

Bill
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on January 04, 2017, 03:22:11 AM
Congrats Mr. Willy, your persistence has paid off; very nice!


Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 04, 2017, 01:41:44 AM
Wow .thanks for all the comments and I'm glad you all like it. It was well worth all those long hours and head scratching in the middle of the night. Now comes a lot more work on the motion work that will be more like watch making !! I also like everybody else's work on here that i would find quite difficult to emulate !!  some pics of the correct motion work and straps to make next. When making the substitute motion work it was quite amazing how minute adjustments made evening free up and move effortlessly !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 04, 2017, 09:40:17 PM
[quote author=sco
Still following studiously Willy.  What do you think the stepped cone was for just inside the eccentric?

Hi Simon , I think the stepped pulley may also have been used to drive the indicator to produce the graph for the cylinder pressures. Once drawn the would have used a planimeter to work out the horsepower of the engine. I do have an old Elliott example myself ,so i could make a miniature indicator to put on this engine !! That would be fun !...........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on January 04, 2017, 11:52:21 PM
Ah, have not seen a reference to a planimeter in a long time. I have one that I use for boat hull design, got it for calculating areas and displacements before the days of software design tools on home computers. Really neat tools, another one where someone had a brilliant moment of thought to design them.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on January 05, 2017, 02:20:00 AM
Nice Willy!     Love the planimeter!....

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 05, 2017, 02:40:59 PM
Nice Willy!     Love the planimeter!....

Dave

Hi dave , yes ,I got it for £20 at a flea market as the chap did not know what it was !! Oldschool stuff is good .......i prefer to say  Olds cool  though. As experts with using this tool, can one use it in reverse to plan out a certain area that you may require ??
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on January 05, 2017, 05:25:14 PM
Reverse plotting out an area wouldn't really work, you could draw a number of curved areas and measure to find what they are by trial and error though.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 06, 2017, 03:46:13 AM
Reverse plotting out an area wouldn't really work, you could draw a number of curved areas and measure to find what they are by trial and error though.

thanks for the info...      I have now had to remake the motion hanger pins as the first ones that were drilled and tapped for 10BA broke off because there was not enough meat on them, new ones have been made using 12 BA bolts and, because the accuracy is not that critical i have used a heavy duty automatic drill chuck. this is used, as, being quick release the job doesn't take too long when removing and installing the rods
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Zephyrin on January 06, 2017, 10:18:57 AM
Great job you are doing with this unique early engine, industrial archaeology and model engineering, inspiring thread !
I made an ETW's "Vulcan " beam engine in the past, I see now that I should have done the square nuts as in the plan...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 07, 2017, 05:59:38 PM
63c9KR0bqb8
Hear is the video showing the workings of the Electrically heated steam engine, also the more detailed version that appeared in EIM a few years ago
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 09, 2017, 12:10:34 AM
I have had to make some bolts different lengths so i have had to make this simple device.......it was some lateral thinking when someone wanted a lightweight bowden cable cutter when cycling to Japan !! it is made from silver steal and at the moment is in its unhardened state it also works well on rivets.......I have not seen this before in my ME mags and i am sure someone else has also come up with this idea.......The problem with most cable cutters is that the shears move apart and don't cut ,however with this device the shear faces can not separate....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 20, 2017, 01:09:41 PM
More work on the Radius reach rods .........I have used square stock as this is easier to hold in the vice when filing up. I have also turned the ends up round and support them in a brass bush in the tailstock chuck, i find this easier to hold work as i have found when using a centre this can heat up ,expanding the rod so causing the headstock to jam up and slow down ,also the stock is held really rigidly preventing distortion when turning down. The rod end that attaches to the support bracket is made in two parts and so to make it easier to file and drill accurately the parts are silver soldered together ,filed and drilled then reheated and parted. ...................
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 20, 2017, 01:13:13 PM
More pics.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 27, 2017, 02:36:29 AM
The lower air pump crosshead has been made and the parts silver soldered together. The motion work is quite complicated and will have to be very carefully measured up so all the parts fit. !! I am having to make the parts not quite to the drawings so they will actually fit and work, so this part had to be taken apart and re dimensioned.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on January 27, 2017, 02:41:16 AM
That's some delicate work, very nice!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Rivergypsy on January 30, 2017, 12:37:18 PM
Looking good!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 01, 2017, 02:48:52 AM
The air pump straps are made next. they are made from square stock so when the holes are drilled using the brass template, they are kept in correct alignment. Once drilled they are filed to shape....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 01, 2017, 03:09:49 AM
Thats a clever way to do it! Looking good.


What is the purpose of the air pump in the engine?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 01, 2017, 02:39:30 PM
Thats a clever way to do it! Looking good.


What is the purpose of the air pump in the engine?


Ok the "Air pump" is used to drain the "condenser" (bit of pipe below the engine where the exhaust steam goes) of the water that is squirted into the exhaust steam to cause a vacuum to help the engine be more efficient. this water that accumulates has to be got rid of, so, there is a water pump that pulls it  up out of the way and sends it to the boiler via another pump that is connected by a shaft on the other side of the beam. Sometime in the past someone has decided to call this the Air Pump as it does have some air in it. some pics of the arraignment.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 07, 2017, 02:12:56 AM
I have continued with the motion work and have had to remake the radius rods. on the prototype the air pump crosshead did not fit under the beam and so part of the beam has been chipped away !! i will also have to do this with the model. This seems to have been a common problem and on some engines there has been a modification to fix this. This can be seen in the first photo......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 07, 2017, 03:38:43 PM
2 More views of the chipped away beam to accommodate the air pump crosshead..........There is a Norwich society show and tell event tomorrow on wednesday and i will be taking this engine still unfinished to the event...........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 07, 2017, 04:00:35 PM
Interesting to see that even the builders of the real thing had the occasional "whoops" moment!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 12, 2017, 02:08:26 AM
More work on the motion parts...the coupling rods are made and fitted. I have used this tool to get the right dimensions...as the two plates are at quite a narrow angle, one can read off the sizes of the shafts and quickly calculate how much to remove.....1/1000 being about 1/16" so easy to see.....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 12, 2017, 02:19:29 AM
Interesting to see that even the builders of the real thing had the occasional "whoops" moment!

I think the reason for the beam needing this quick fix is that it was possibly an already made pattern that was not meant to be used with an air pump rod. To get perfect parallel motion the centres of the crossheads have to be in a straight line drawn from the centre of the beam bearing to the bottom centre of the beam end crosshead. that is why the HP strap has the piston rod crosshead slightly higher that the coupling rod link. The HP and the LP links are to be made next then the engine is basically finished apart from the condenser and air pump.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on February 12, 2017, 02:57:26 AM
Beautiful work, Willie, beautiful.

 :popcorn:

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on February 12, 2017, 09:21:27 AM
Hi Willy,
 I've got spider who would be proud of the web you are building!
This engine is going to be mesmerising when its running!

 :popcorn: :popcorn:

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 12, 2017, 03:35:37 PM
Thanks for the  comments from fellow MEM'ers more on the Beam castings .........There are many instances where they used old patterns for new engines ,rather than making new ones......on the Bridewell engine there is a spare hexagonal hole and ...another engine where the lugs are not used. also a better picture of a "modified " beam to incorporate the air pump clearance.....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 13, 2017, 03:54:53 PM
Saw this paragraph from an 1872 book about steam.................................!!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 13, 2017, 04:40:56 PM
Saw this paragraph from an 1872 book about steam.................................!!!

Well, I'M not going to test it!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 15, 2017, 02:34:34 AM
Saw this paragraph from an 1872 book about steam.................................!!!

Well, I'M not going to test it!

I shan't either ,,,,,,,,,,!!
I am now making the LP strap   ,  this is quite a complicated looking part and i shall explain it bit by bit. this drawing was made over 2 years ago so i have had sometime to work out how to do it. I have started with a piece of 1" x 1"  x1/8" angle it has been marked out and two holes drilled at each end. The slot is then milled out and the bottom hole is filed square to allow the brass bearing to be filed to fit the aperture and then slid up to the top of the strap and the curves filed to fit The angle is then milled to thickness and............more later.........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 15, 2017, 03:11:03 AM
That is a fascinating part and great solution to making it!


 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 16, 2017, 02:46:16 AM
The bearings are next drilled and the corners turned off to give a guide to filling the slots. When filling the slots i use a round file first, then finish with square  file. this is to keep the  file central and stops it from sliding sideways. the bearings are made in one piece and a slot sawn to denote the split. I am using one of the old straps as a template to make the lattice part the right length. this is made from the same bit of angle and will be filed to the correct width and length. the holes for the gib and cotters are drilled out and filed to shape with my special Valorbe files, The lattice parts will have the inside filed square then the diagonal parts will be added later.....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 17, 2017, 02:00:24 AM
further work on the  straps , i have had a go at the lattice work and have made one with a bit of trial and error   ( R & D )  and the tecnique seems to work, but will have to make the next ones properly, However looking at the originals they are a bit hapazadely constructed.................
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on February 17, 2017, 02:11:44 AM
Still watching, Willy.  :popcorn:

It's a fascinating and worthwhile project.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 17, 2017, 02:33:43 AM
Still watching, Willy.  :popcorn:

It's a fascinating and worthwhile project.

It has been both  interesting and informative constructing this engine ,and i feel quite privileged with the help and access given to me by the Beeleigh Mill  restoration group to be able to make this engine. I have learnt so much about steam engines as well as this is an original and unrestored or modified engine. Here is a pic of one of the straps lattice work !!. I used to make kits that was interesting but you only get a fairly simplified set up ,however they are helpful to get people started in this hobby, to then go onto other projects.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: billmac on February 17, 2017, 04:06:01 PM
Saw this paragraph from an 1872 book about steam.................................!!!

I can't refute this from first hand experience (not having been scalded by high pressure steam), but everything I have learned about steam says that this advice is seriously wrong. The temperature of high pressure steam is obviously high and heat flows from a high temperature to a lower temperature (your body). A rule of thumb is that a steam scald at a moderate pressure is about 10 times more destructive than a typical water based scald. Added to this is the fact that steam is transparent and if coming from a high pressure source is invisible. The speed with which steam issues from such a source is sufficient to cut chunks out of you as well as simultaneously cooking you. An old steam guy once told me that if you know that a steam pipe has let go in your vicinity, but you aren't sure where, the last thing you should do is walk around looking for the leak. If you walk into the steam jet (invisible) that might be the last thing you do. And if it doesn't immediately kill you, you will wish it had.

Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 17, 2017, 05:38:22 PM
Saw this paragraph from an 1872 book about steam.................................!!!

I can't refute this from first hand experience (not having been scalded by high pressure steam), but everything I have learned about steam says that this advice is seriously wrong. The temperature of high pressure steam is obviously high and heat flows from a high temperature to a lower temperature (your body). A rule of thumb is that a steam scald at a moderate pressure is about 10 times more destructive than a typical water based scald. Added to this is the fact that steam is transparent and if coming from a high pressure source is invisible. The speed with which steam issues from such a source is sufficient to cut chunks out of you as well as simultaneously cooking you. An old steam guy once told me that if you know that a steam pipe has let go in your vicinity, but you aren't sure where, the last thing you should do is walk around looking for the leak. If you walk into the steam jet (invisible) that might be the last thing you do. And if it doesn't immediately kill you, you will wish it had.




Yes i totally agree with what you have said .......i have talked to a few people that have witnessed this and they all say the same thing about the dangers of steam leeks, this book was obviously written by an   Academic   rather than a steam worker ......This book was written by someone called Henry Evers.  The front page is missing so do not have any info about him.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 19, 2017, 03:05:57 AM
The new strap stretcher has been made .the sides are 1/4" so at 1/16 th scale the thickness of the sides is 15/10000" thick which is quite small. what i have done is to file this part so the wall thickness is tapered to give more stability to it.,,bit like the draft in the wooden patten !!I have made a small jig to make this easier and the slots are filed out and the diagonals silver soldered in. this is done in two stages. so this second attempt is a bit more presentable and i am reasonably happy with it. so only 3 more to make.....................
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 19, 2017, 10:01:24 PM
Those are looking great!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 24, 2017, 03:00:27 AM
I have made a start on the HP strap and it seemed to be going well but it is smaller than the LP strap so was a lot more fiddley, This will have to be made again but with much thinner diagonals. so it will look a bit like this when made properly................
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on February 24, 2017, 05:40:55 AM
Willie, I thought you were doing some very fiddley bits when you started this project, but now the parts are sooo much smaller and more complicated!!

Excellent work!

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 25, 2017, 12:06:37 AM
Wow, very fiddly bits, but the result is amazing.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 26, 2017, 03:08:33 AM
Yes these bits are fiddly and i am going to make the spacer parts again using much thinner diagonal parts .the gibs and cotters have been made however and the straps filed to size..........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 02, 2017, 01:39:29 AM
I have another go at these tiny spacers and have used 20 Thou steel for the diagonals. I have also used thinner silver solder to hold them in place. I have cut grooves in the parts to hold the silver solder in position, using this thinner solder stops the holes filling up with too much solder. So, this new one is a bit better..........Also a corliss ship engine i found in The Engineer from 1876.......Also if you look at the lettering on the modern penny, you will find it is not very good, this is because they are made from steel rather than copper......just something for the Numismatists  amongst us !!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 02, 2017, 02:19:15 AM
Just incredible tiny bits!


I like the marine corliss drawing, an elegant design.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 02, 2017, 02:53:30 PM
Just incredible tiny bits!


I like the marine corliss drawing, an elegant design.

Hi, I  included the Corliss engine because i think i read in previous comments somewhere that they didn't have Corliss engines on steam ships ? this is from the Engineer  October 20TH 1876 if you want to look it up on Graces Guide.....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 02, 2017, 04:13:40 PM
I was not familiar with Graces Guide or The Engineer - just took a browse through a couple issues, some fantastic illustrations and articles!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 02, 2017, 11:32:05 PM
I was not familiar with Graces Guide or The Engineer - just took a browse through a couple issues, some fantastic illustrations and articles!


Everybody should know about Graces Guide  !!!!!!! i am slowly working my way through it......... It started in 1856 and i have got up to 1876 at the moment and the engravings are superb   :praise2: :ThumbsUp:............It is a weekly paper that covers so many fascinating subjects........I love it....and it is still being published.........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on March 02, 2017, 11:36:14 PM
Still following along Willy.  :popcorn:

It's not just the project (as great as it is), I like the story behind it.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 02, 2017, 11:47:26 PM
Still following along Willy.  :popcorn:

It's not just the project (as great as it is), I like the story behind it.


There is quite a lot of info about it with old photos on the web and the Restoration group are doing a Sterling job.every cubic inch has to be looked at and vette4d by a millwright and English Heritage and the local council , so it is going to be quite a lengthy project. they have plans drawn up as well to make a new Boiler system as the original Elephant boiler will not be used even though it is in really good condition.There is a Hurst connected to it complete with a Wallover..!!?? ETC ETC ETC
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 03, 2017, 02:05:50 AM
so, the straps are now made but i may do some of the spacers again. the LP crosshead and the Airpump shaft have to be made. here are some pictures of the elephant boiler. the Hurst (corn grinding ) equipment. they have taken the main steam valve apart as well. So the condenser and steam pump to make next. Lso an original unused piston for this engine from about 1840..!!!!!!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 09, 2017, 02:20:46 AM
ok ,so the engine is on the home strait now, although there is a lot of hidden detail still to do with the air pump and condenser to make also the feed water pump to construct. most of these parts will not be visible from a front on photo so it will not look much different from this pic...........quite a short post for two years work !!!!!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Flyboy Jim on March 09, 2017, 03:33:21 AM
This is really coming out nice. I love all the detail!  :ThumbsUp: It's going to be nice to see it in action.

Jim
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: fumopuc on March 09, 2017, 04:52:18 AM
Hi Willy an excellent job. The details are fantastic.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 09, 2017, 12:51:11 PM
here is a better picture in daylight........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on March 09, 2017, 01:01:08 PM
Beautiful!  :ThumbsUp:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on March 09, 2017, 07:19:16 PM
Damn nice work Willy and she's a beauty for all the work you put in. Your the man Willy and your craftmenship shows........ :praise2:


 :drinking-41:
Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 09, 2017, 10:06:48 PM
Thanks for all the comments........I do not have a really good photo to compare with the original as it is tucked away in its building with lots of wooden scaffolding around it ..Health and insanity etc
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 09, 2017, 11:39:01 PM
Beautiful!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on March 10, 2017, 12:23:58 AM
Impressive work Willy! :ThumbsUp:


Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: plataman on March 13, 2017, 03:12:56 AM
Excellent work! Makes my models look like Tinker Toys. Tomorrow morning I go out to my shop and throw away everything I ever made. Texas Terry
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on March 13, 2017, 03:50:06 AM
Nicely Done Willy!!! 

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 18, 2017, 03:19:32 PM
Thanks for all the encouraging comments and am now making the below the decks parts of the condenser and air pump, some of this is guesswork as i cannot see inside these parts so i have to make it up as i go along........The drawings are made and the condenser part is made There is a gland here as there is some movement is required to take up the expansion due to the temperature differentials. This uses the gland adjustment device that is used throughout this engine. I have made the nubs for the adjustment bolts by drilling through with a small drill, then silver soldering the drill in place and grinding out the middle part with a diamond bit in the Dremmel. This keeps the nubs in line and also makes a handy handle to hold the part. The drill will then be ground off later. Using the tang of the drill makes for a good strong fixing for the bolts. These bolts were also made with square threads so that only one nut is required to adjust them..............
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 18, 2017, 10:52:02 PM
The other parts of the condenser expansion gland are made but need to be tidied up. the gland bolts are turned and threaded 10BA. when i make these small components i turn them with a taper to stop them bending at the extremity, they are then threaded with the tailstock die holder and then finish turned afterwards. I use square bar stock as i can accurately drill the cross hole and also make it easier to file up in the vice with more precision using the square faces as datums. ...........I have also used the decimal inch gauge that makes sizing the small diameters easier. as this is an analogue measuring tool it is very quick to use and hold.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 18, 2017, 11:10:48 PM
Very nice as usual, I like your drill bit trick.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 20, 2017, 02:01:15 PM
STOP PRESS,.....some Breaking News about the Beeleigh mill engine..............they have just managed to turn the engine flywheel 45 degrees after much lubrication and gentle tapping with a wooden mallet !! They still need to separate the engine from the flour mill, But things are looking good for this restoration project. This is the first time it has moved since 1875 !!! so good old victorian engineering and whitworth nuts and bolts that will always be removable !! No pics yet  but further info will be released................YEA...........Some old photos from the 50's
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 20, 2017, 05:45:04 PM
Exciting news! Bet there were some wide eyes and big grins!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on March 20, 2017, 06:40:43 PM
Why do Whitworth threads come free from rust better than 60* threads??

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bluechip on March 20, 2017, 06:53:15 PM
Probably because 'Whitworth' threads are a coarser pitch, rather than thread angle. Maybe UNC lets go before UNF ??

Does seem to be true, maybe any penetrating fluid gets in better.

BSF or BSCycle ( 26 TPI ) often shear rather than unscrew  ...  :'(  been there many times ...  :facepalm:

Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 23, 2017, 12:33:16 AM
Started work on the air pump. I will be making a perspex maquette first as a demonstration model to see how the flap valves operate. first the outside 'casting' is turned up . the other piece of perspex is to locate the drilled holes in the bottom part that joins the condenser and air pump together.As there is a lot of overhang at the top of the air pump housing it would be difficult to spot the holes through to the base.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 23, 2017, 01:00:39 AM
Its great to see the details that are usually hidden away. Great stuff!


 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on March 23, 2017, 01:37:23 AM
This is really cool stuff, Willy!! I'm still amazed that those badly rusted parts still come apart.

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 23, 2017, 11:44:14 AM
This is really cool stuff, Willy!! I'm still amazed that those badly rusted parts still come apart.

Pete

Talking about taking things apart ,this is the main steam valve that 'fell' apart when they undid the bolts !! the central rod is the governor valve and that is proving a bit more tricky. Also a pic of the mill in the 1950's with its chimney, that has now disappeared. They are a bit concerned about the corrosion but i said that actually all those small indentations will provide its own seal under steam......is that correct ??
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 26, 2017, 02:15:50 AM
More  work on the perspex air pump and condenser housing, the top flap valve is made and it uses a piece of chamoise leather as they flap part. this would have been leather or latex rubber on the original and later valves used thin brass or bronze plates. the holes for the base part uses the turned flanged disc to drill the holes in the correct places. there will be a flap valve as part of the piston and also another between the condenser and air pump.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 27, 2017, 01:39:35 AM
I have continued with the air pump and have made the condenser pipe and the bottom ball valve. as this is perspex i have made a brass seating for the the valve ball. so just the piston valve to make and then i can make the real item out of brass. I like to make these small maquettes to see how it will go together so i don't make any mistakes with the noble metals.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 27, 2017, 02:16:46 AM
That works out great. Did you keep the perspex parts from earlier in the build? Bet they would make a nice side display to your engine to show how the inner mechanism works.


 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 28, 2017, 02:58:23 AM

Beeleigh mill air pump operation
The Air pump and Condenser parts are now made and here is a short video of it working .The photos show the flap valves and the transfer holes to pass the air/steam or in this case Tea out of the condenser pipe to the upper chamber of the air pump that is then transferred to the boiler feed pump and the overflow.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on March 28, 2017, 03:17:42 AM
Thanks for the video! Hope the tea was cold.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on March 28, 2017, 11:03:19 AM
Tea? Isn't there a law about that where you live?  ;D

 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 01, 2017, 01:27:54 PM
Tea? Isn't there a law about that where you live?  ;D

 Hi, There is a law about this yes,unless one is a teetotaller !!?

Have started on the proper air pump sub assembly and will make it out of brass, I have sawn it out of a large lump !! and as my mum also said  'let the tool do the work' so it didn't take too long !!I have also used the plastic template to 'spot' through for the holes.............I have been using 'small woods decimal gauge and noticed that they used the same divisions from a metric rule to get the thousandths of an inch graduations. this gauge only measures up to 1/8". I thought it would be quite easy to make my own from two rulers to measure wider distances......will keep you posted...........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steamer on April 01, 2017, 01:32:49 PM
You crack me up Willy!     Nice demo!   I like that one a lot!

Dave
 :lolb:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: sco on April 01, 2017, 03:11:32 PM
You crack me up Willy!

Dave
 :lolb:

Me too!  Still following your progress,

Simon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 03, 2017, 02:30:56 AM
more work on the air pump, the condenser and the air pump cylinders have been turned up and will be bolted to the base with 10BA square headed bolts the condenser gland has 12BA square headed bolts. these will be filed up from standard hex headed bolts from EKP.......incidentally his bolts and nuts have different size a/f heads as he makes the bolts but buys in the nuts !! so i have two different size spanners and nut runners.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 04, 2017, 02:11:42 AM
More work on the base 'casting' milling and filing etc etc......This is almost the last part to make so getting there slowly........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 04, 2017, 02:16:49 AM
Impressive!


 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 07, 2017, 01:35:30 AM
M making the bottom valve twixt the condenser and air pump. i am using a Nitrile ball and after boring out the connecting hole have made a seating for the ball, this is slightly convex and the bore is smaller than usual to stop the ball being sucked into it !! this tube is loctighted in place ant is pushed in using the other long tube. the ball is held in place with a very light spring. also a pic of where it is being installed under the base plate.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 07, 2017, 01:38:24 AM
Neat, never knew that they made balls in nitrile. Are they about like an o ring for hardness? Will it flex a bit to help seal well?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on April 07, 2017, 04:33:22 AM
Hi Willy,
 That's looking real cool!
Haven't said much lately but have been following along!

On the nitrile ball front, I use them in the boiler feed water clack valves on my loco...they work really welll. The only down side I found is that after awhile they seem to either go out of round, or get the seat marks in them. Found this out by chance after having the steam blow back, & replacing them they worked fine for a while longer. While investigating what was going on I did the suck blow test & was getting a seal then no seal! Have since seen somewhere that instead of a nice square faced hole that you need for stainless balls you need to have a taper for the ball to sit in, not sure how much sorry. I guess the idea is to give a bigger seating surface.
Recently saw a reference to ceramic balls for something else I was looking at, & think I may give these ago with the square hole to see how they work. My clacks have pressed in seats so not to much of an effort to replace, but Chris's elves while nick them if I take them out!

Cheers Kerrin

Whoops Chris, they are harder than orings
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 07, 2017, 03:24:29 PM
Hi Willy,
 That's looking real cool!
Haven't said much lately but have been following along!

On the nitrile ball front, I use them in the boiler feed water clack valves on my loco...they work really welll. The only down side I found is that after awhile they seem to either go out of round, or get the seat marks in them. Found this out by chance after having the steam blow back, & replacing them they worked fine for a while longer. While investigating what was going on I did the suck blow test & was getting a seal then no seal! Have since seen somewhere that instead of a nice square faced hole that you need for stainless balls you need to have a taper for the ball to sit in, not sure how much sorry. I guess the idea is to give a bigger seating surface.
Recently saw a reference to ceramic balls for something else I was looking at, & think I may give these ago with the square hole to see how they work. My clacks have pressed in seats so not to much of an effort to replace, but Chris's elves while nick them if I take them out!


Hi ,thanks for the info,  and...is there any info from the manufactures about metal and profiles for these items ??
Willbert
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on April 07, 2017, 10:57:29 PM
Hi Willy,
 I've never looked. A few guys in this part of the world were using them & having great results, so I got a couple to try. As I said they worked well for a while, then started to pass. They weren't very expensive that I remember so I just replace them when I get annoyed at the leak!
As my loco has been in the shop for repairs for far too long, I haven't done anything about making new seats with the taper but it's on the to do list, just not near the top!

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 08, 2017, 02:45:51 AM
Thanks for the nitrile info.........The rest of the air pump is made so now it can be installed in the engine .....then the feed pump to make......then remaking some parts etc etc etc. you may notice one of the gland bolts is missing !! thats because i have lost it ! those WKSP gremlins again.....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 13, 2017, 02:05:23 AM
The Hot well assy is made and after drawing it up and trying it out the proper one is made from 18G copper. it is sawn out on the mini bandsaw then filed up and some of the bends made using the bending tool. The other bends are made with dead reckoning, then cobbled together and adjusting the parts to fit !! it is now bolted together and after some pre fettling will be tinned up and then riveted  and finally soldered together.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 13, 2017, 02:07:33 AM
More pics with the copper hotwell....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 13, 2017, 02:51:11 AM
Looks great!


If I understand correctly, the hotwell would have some level of water that the exhaust steam goes into, to be condensed and pumped out? Was this so the water could be recycled back into the boiler?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 13, 2017, 03:05:47 AM
Hi, the Hotwell name is a bit of misnomer as the water in it is cold, usually from a river /stream and it actually is squirted into the condenser, hence the name jet condenser. this water mixes with the steam fr m the cylinders and is pumped by the air pump into the `boiler feed pump container and any excess is returned to the river/ stream  This engine is quite crude as there seems to be no provision for cylinder lubrication with an oil supply or any water /oil separator ?? perhaps the low pressure  unsuperheated steam was used as the "lubricant" !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ChuckKey on April 13, 2017, 02:33:27 PM
An air pump pumps the condensate out of a condenser into a hotwell.  From there it may be pumped into the boiler. The main reason for having a condenser is to provide a vacuum (except at sea, where fresh water for the boiler is more important).
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 13, 2017, 03:37:42 PM
An air pump pumps the condensate out of a condenser into a hotwell.  From there it may be pumped into the boiler. The main reason for having a condenser is to provide a vacuum (except at sea, where fresh water for the boiler is more important).

Yes ,also ,they only used jet condensers where they had unlimited supplies of fresh water from a river so they would not have to pay vast sums of money to the local water board. There are lots of different configurations for these air pumps, hotwells, condensers ,et al and at this time there was still lots of experimentation going on. Also the water in the air pump tank does become warm and this goes to make the boiler feed water less cold so more efficient  as regards fuel consumption.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 13, 2017, 05:25:59 PM
Thanks for the info on the hot well/etc!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 17, 2017, 12:27:12 AM
I have now finished the codeser/air pump housing and connected it up to the base plate. there is hardly any room inside their box to work on any of the inside components, so the jet condenser valve and water level and drain cocks may be for show only.  The boiler feed pump is the next part to make...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 17, 2017, 01:04:40 AM
Very nice! Its amazing how much there was under these engines that almost never got seen.

 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 17, 2017, 12:37:12 PM
Very nice! Its amazing how much there was under these engines that almost never got seen.

 Yes you are right, but, most of it is rusty, dusty, very wet and relatively incomprehensibly !! here are some pics of the sister/brother engine at the Ramm brewery that is quite moist !! ;D ;D also next to the hotwell is the foot well and also a mention of the hotwell as in steam boats....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 17, 2017, 01:33:09 PM
That one curved pipe looks like there was an "uh-oh, now what" moment as they were assembling it!


And now you need to model the feet in that footwell!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 26, 2017, 12:21:39 AM
Beeleigh Mill steam test 2NOT YET RATED
from robert Bailey8 minutes agomore
This is a video of the latest steamiest of the model withe the air pump and motion work attached. i went to the Mill today with the engine and will post more pictures and video later. so ,it all works again so just have make the boiler feed pump.....

Beeleigh Mill steam test 2
Anyone
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 26, 2017, 01:06:44 AM
That is wonderful! The motion is terrific!


 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on April 26, 2017, 02:50:54 AM
Willie! That's a beautiful motion to watch. And you've made it all to scale and it all works. Outstanding!!!

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on April 26, 2017, 08:50:11 AM
Brilliant Willy!

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ShopShoe on April 26, 2017, 01:56:54 PM
That is nice to watch.

When it is all done it will a very nice model, indeed.

ShopShoe
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 26, 2017, 05:50:19 PM
Thanks for all the nice comments.......here is a link to the sister engine at the Ramm brewery Wandsworth engine....HMBFT-qilo0   This is the sister engine but it has been updated over the last 180 years !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Don1966 on April 26, 2017, 07:03:34 PM
Just awesome Willy and the motion is great to watch...... :praise2:

Don
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: sco on April 26, 2017, 08:35:33 PM
Brilliant stuff Willy!

Simon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on April 26, 2017, 11:17:55 PM
Awesome Willy!  :pinkelephant:

It has been and continues to be a very interesting journey.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 27, 2017, 01:53:08 PM
Thanks for more comments ,!!!! yes it has been quite a journey and the ETA is not yet in sight!! here is a video of the engine being turned over by hand using the flywheel

Beeleigh mill flywheel rotation
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 27, 2017, 02:22:24 PM
Here is a video of the engine demonstration at Beeleigh Mill, This was outside the mill and you can see the Elephant boiler in the background. also the film group and members of the restoration group looking at the engine !! also the beam in its raised position.......

Beeleigh Mill engine filming
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 27, 2017, 03:18:14 PM
Wonderful!


Do they have an estimate on when the original engine restoration will be done? Fantastic that it is being saved.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 29, 2017, 01:57:22 PM
Movement of the beam at Beeleigh mill

Beeleigh mill beam movement up

Hi Chris ,This is going to take a long time still yet i'm afraid but something to look forward to !!
Beeleigh mill beam movement.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on April 29, 2017, 02:12:04 PM
Slow but sure progress, getting that beam movement had to be an exciting step, it is cleaning up nicely.


 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 18, 2017, 03:30:58 PM
Just got back to work and another letter arrived from the council housing bloke and i have another inspection to check up on the progress with the "clearing the property"  >:( anyway here is the start on the boiler feed pump... The water goes in the tank and then gets pumped into the boiler ,however i don't know how the water enters the down pipe where the brass pump rod is ?? there must be some small holes where the water goes to get to the other side (bottom) of the pump rod ?? so this may be a dummy representation of the pump. Also there is no parallel motion arraignment to keep the rod vertical so there may be quite a bit of 'flexing' going on...Any ideas on this....I have made a drawing of what i can see.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: ChuckKey on May 18, 2017, 09:43:07 PM
I think you are showing angled through holes from the tank to the pump bore. If so, this won't work without some kind of valve to close the holes off on the down stroke.

I suggest the plunger might have some kind of cut-away at the bottom end, perhaps diagonal, so that during the up stroke a partial vacuum is created in the pump chamber and towards the top of the stroke the 'missing side' of the plunger allows water to rush into the pump. A short way back down the down stroke the plunger would again fully occupy the gland and commence pumping. If this is how it works, I would expect the gland to have been troublesome. A hole up the end of the plunger communicating with a cross hole to let the water in might not be quite as bad. 
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on May 18, 2017, 11:09:48 PM
Fascinating.
I always think about the people, who many years ago, built the walls, made, installed, and ran the engine. Not knowing anything about the times and people who, many years later get to enjoy it all.

Nice stuff Willy.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 19, 2017, 02:28:49 AM
Hi, ChuckKey, Thanks for the reply,  i did think about the same sort of arrangement but with a slot rather than an angled cut as this would have a better flat ,horizontal  :edge: to have a better seal . unfortunately the brass plunger is disconnected from the beam so one cannot see the rod at its full up position. As you say ,this could be troublesome as it would interfere with the packing !The reason i thought there might be those Drillings is that the two lugs that hold the gland in place have to go through the bottom of the box and this would give a space for the water to enter below the bottom of the brass plunger ??
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on May 19, 2017, 09:12:06 AM
Hi Willy,
 Still following & still enjoying!
Fascinating how the old boys did the builds given that they were inventing this stuff as they went along!

As an idea on the pump, maybe the bottom of the ram has a seal a bit like a bike pump, pulls a vacuum on the upstroke & sucks in the water then seals on the down, just a thought.


Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 30, 2017, 01:48:08 AM
Ok more work on the boiler feed pump.....the tank is connected to the base i the correct position and the pump pipe bolted on . .......This is the last part to make before i finish all the other parts properly before painting. Also went to Strumpshaw Steam Rally and got this Ball vice that will be really useful and this bound collection of magazines that has an engraving of a corliss beam engine from 1882 !!...and got to change the tyre on  my push bike......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on May 30, 2017, 02:32:51 AM
Very nice! Gotta go make more popcorn...   :popcorn:


That Corliss valve beam engine is interesting. It looks like there are only one valve at each end of the cylinder, rather than a separate intake and exhaust valve at each end. Was that a typical Corliss setup? Or an early version?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 30, 2017, 02:56:40 PM
Hi Cris, this engine was built by Thomas F Rowland ,Continental Works  Greenpoint Brooklyn in 1881/2   In the writeup it says there are but two steam chests, the exhaust valve is inside the inlet valve, I shall get a copy of the full writeup later..............
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on May 30, 2017, 03:11:45 PM
Hi Cris, this engine was built by Thomas F Rowland ,Continental Works  Greenpoint Brooklyn in 1881/2   In the writeup it says there are but two steam chests, the exhaust valve is inside the inlet valve, I shall get a copy of the full writeup later..............
Nested valves, sneaky!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on May 31, 2017, 01:20:28 AM
Hi Chris, this is the explanation  of the engine...........hope you can read it
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on May 31, 2017, 02:04:28 AM
Hi Chris, this is the explanation  of the engine...........hope you can read it
Very interesting description, thanks! Amazing how many variations of each component there are.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 01, 2017, 01:50:09 AM
I have attached the cross bar to the boiler feed pump tank and bolted on the air pump assy to see how it all goes together.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Flyboy Jim on June 01, 2017, 03:12:25 AM
Intersting article. I only understood a little of it, but what really hit home was that this was all "state of the art" 125 years ago. Makes me wonder what "state of the art" will be 125 years from now, compared to todays "state of the art".  :shrug:

Jim
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 07, 2017, 01:17:39 AM
The engine is now ready for finishing the details and painting. I have been making the casting webs detail on the air pump tank with brass and nickel silver bar that is the correct sections. Nickel silver is still available in lots of different sections on the web. Also some BA spanners i bought at the Doncaster show, these are available from  2 to 12 BA and are lazer cut in stainless steel.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 07, 2017, 01:30:56 AM
I love those spanners! Are they available online? Great detail pieces for models.


Can you post a link or two for the nickle silver sections? Have not seen them around.


Looking forward to seeing the model finishing process... :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 07, 2017, 10:53:01 AM
H i Chris, The spanners came from one of the stalls at this years Doncaster show but i did not take a note of who they were ,perhaps somebody else knows who went there, The ring spanner ends are really good at holding nuts and bolts in awkward places !! There are numerous Nickel Silver suppliers here in Blighty and if you type it in you should find somewhere in the states. It is quite a large industry and there are sites selling it for jewellery and other small end users...The lombard is looking really good, will post more stuff soon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 07, 2017, 02:35:42 PM
H i Chris, The spanners came from one of the stalls at this years Doncaster show but i did not take a note of who they were ,perhaps somebody else knows who went there, The ring spanner ends are really good at holding nuts and bolts in awkward places !! There are numerous Nickel Silver suppliers here in Blighty and if you type it in you should find somewhere in the states. It is quite a large industry and there are sites selling it for jewellery and other small end users...The lombard is looking really good, will post more stuff soon.

I have been looking, but must not be hitting the correct phrase in my searches - lots of suppliers for the sheet stock and round bar, but thats it... Nothing with other section shapes.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 07, 2017, 09:36:05 PM
Hi Chris, I bought mine some time ago so can't remember exactly where. Here are a few links i have found....I don't think the suppliers put on every size they do, but if you contact them they may have it in stock........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 07, 2017, 09:51:35 PM
Thanks, I will check them out!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 12, 2017, 02:03:58 AM
Am now finishing the engine..lots of square headed bolts to make. i use the hardened steel thread gauge for this, using hex headed bolts and filling them square.  painting has started with the acid etch paint first as this is mainly brass and copper.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 12, 2017, 02:06:27 AM
Those square head bolts look great, nice touch!

 :popcorn:
 :popcorn:
 :popcorn:
 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on June 12, 2017, 06:30:21 AM
Hi Willy,
 The square head bolts are making a great difference! Much more in era!

The detail on the end of the sump adds a lot!

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: fumopuc on June 12, 2017, 06:58:52 AM
Hi Willy, always impressive to see your progress.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Roger B on June 17, 2017, 08:13:43 PM
Great progress as ever, I like those laser cut BA spanners  :ThumbsUp:  :wine1:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 19, 2017, 12:46:28 AM
Hi, the spanners came from    Model Engineer Laser......that i bought at Doncaster show this year.   More pre painting work.  When i set up the valve events i left a spigot on the eccentric sheave with 4 gru/b screws to get it in the correct position in relation to the crank. Now it is in the right place i have drilled through the sheave into the crank shaft to position a pin, and the rear part of the sheave will be removed. This pin will be locktited in place before the strap is replaced. I will remove the shank of the drill to use as the pin as this is good quality steel and is the same size as the drilled hole.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 23, 2017, 04:13:53 PM
more work on the eccentric sheave, the rear part is removed and the spaces drilled and filled out using the edge of the removed part as a guide to work to. As this would have been a two part pattern casting, the profile is slightly tapered on both sides towards the middle. This makes it easier to file from both sides so as not to cut too deep and loose the correct shape on either side.Also as a casting the inside would not be machined, only fettled so the finnish will have a bit more of an as cast look to it.!! Also seen in another post...is this item a rather posh die holder or a convenient holder when using dies of different sizes when threading a rod of differing threaded portions ??
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 27, 2017, 09:32:34 PM
Lx2SYiMbyk0
Hi doing more to the engine getting ready for painting ...in the mean time here is a vid of me making instruments circa 1978............
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 27, 2017, 10:30:50 PM
Fascinating work! At least now we know where you learned the file and torch work.... Do you still do instrument work along with the engines?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on June 27, 2017, 11:36:04 PM
Did you catch that re-saw..... without a fence!!!

"That Boy, I say, that Boy there got the talent early!!"

That's a wonderful video, Robert. Thank you very much for sharing!

 :cheers:

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: MJM460 on June 28, 2017, 01:27:54 AM
Willy,  you leave me in awe.  What magnificent craft.

Nice to see the bandsaw, after serving its apprenticeship, found its real purpose in life.  Loved those clamps, and puss was a nice touch.

Wonderful

MJM460
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 28, 2017, 01:41:45 AM
Thanks for the comments , I don't actually make instruments anymore as my health has let me down...quite hard work using hand tools !!  Now i use machine tools ,much easier... and yes the catgut for for strings came from somewhere else !! Also no health and safety in 1978 just common sense !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 29, 2017, 02:25:01 PM
This is Happening this W/E..........just down the road from me........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on June 29, 2017, 07:20:01 PM
Wish I was a LOT closer - looks to be a fun event, videos, we need videos!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on June 30, 2017, 02:17:19 PM
Hi Chris ,the steam ups are once a month at Forncett and i have been there many times and the next visit will be at the MEM meet up on the 1St October. iSo i will be there and promise to take some video footage then !! In the meantime i will be finishing off the engine and am thinking about a suitable base. I have made the first one from MDF and dolls house wallpaper, but am looking to perhaps making it with real bricks from Stacey's. I have a few samples "free" and to make the correct diorama with full bricks rather than 'slips' will cost about £200 !! this will be a '9'inch wall without queen closers or voussers etc etc.....so will see what happens..............
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 02, 2017, 02:19:03 AM
I have now started painting some of the parts, the base plate and bearing blocks. there are a few more parts to be made but these will have a chance to really dry and harden off prior to assembly. ``i have been using JD weld as a filler but is there a solvent one can use before applying this to make a really good bond....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Ye-Ole Steam Dude on July 02, 2017, 10:46:55 AM
Good morning Steam Guy Willy

On aluminum and brass I use a product called Alumabrite it will clean all oil, surface oxide and etc. I then wash the parts real good with clean water and then dry off with paper towels. Apply the first coat of primer as soon as the parts are completely dry. This is a acid compound so you have to be careful using it.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 03, 2017, 03:16:36 PM
So a few more bits to make    the governor linkage......so ....a lever comes off the governor and goes up to a cross shaft and then back down to the main steam valve. I do not know why it goes up just to come back down again ?? It could just operate the valve by an arm coming off the lower shaft ??.
anyway it is there so will have to feature on the model !!
Good morning Steam Guy Willy

On aluminum and brass I use a product called Alumabrite it will clean all oil, surface oxide and etc. I then wash the parts real good with clean water and then dry off with paper towels. Apply the first coat of primer as soon as the parts are completely dry. This is a acid compound so you have to be careful using it.

I do use the acid etch pre painting paint from Phoenix Precision Paints, am was just enquiring about a solvent to enable the JD weld to adhere to the brass and Nickel silver components.....Thanks for your info.      .a few pics
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 04, 2017, 02:58:15 AM
Ok, so i have been trying out how to make these parts ......there are two of them so two pieces of brass are soft soldered together, then a paper templates glued on and the slots sawn out to feature the casting flanges. the legs are then slotted after soft soldering to a back plate to stop them flapping about. A plate is then silver soldered in position, but left oversize to give some rigidity whilst fashioning to fit the back plate etc, I will see how this turns out and may try something different............
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 04, 2017, 03:34:16 PM
Well this works in principle so will make some more........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 05, 2017, 02:30:53 AM
So this one has been made ...the technique is ok but the execution leaves a lot to be desired so i shall have to make a new pair ...........learning on the job i think it is called,!!......A few pics and one where it attaches to the A frame
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 07, 2017, 02:45:25 AM
The top governor transfer trunnions are now made and in position ....still a few items to make before i can start painting the A frames.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 07, 2017, 02:55:59 AM
Looking great!


 :popcorn:


 :popcornsmall:

Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 12, 2017, 02:38:21 PM
I have made the Governor primary shaft  bearings ,however there we're two, but one of them has totally vanished so will have to make a new one :'(..................
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 12, 2017, 02:44:15 PM
Uh oh, forgot to leave a plate of cookies out for the shop gnomes?   :facepalm:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 12, 2017, 04:06:42 PM
Uh oh, forgot to leave a plate of cookies out for the shop gnomes?   :facepalm:


Hi, It is weird how some things completely disappear......./despair..yes./dissolved....possibly...,discover? hopefully !!
 
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 13, 2017, 03:21:13 AM
more work ........trial assembly to get the position for the governor primary bearing block position/ also the base and bearing blocks will be painted black and the A frames beam  engine and sweep rod will be green. also the base plate with Beeleigh Mill lightly engraved upon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: MJM460 on July 13, 2017, 10:53:12 AM
Beautiful work Willy,  a pity about that bearing, but the extra one usually goes quicker.  When it is complete you will no doubt find the third.

MJM460
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Admiral_dk on July 13, 2017, 11:05:14 PM
It's shaping up beautifully  :praise2: and unless you're going to do the whole setting, building and everything .... you're not far off a finished project  :cartwheel:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 14, 2017, 12:23:57 PM
It's shaping up beautifully  :praise2: and unless you're going to do the whole setting, building and everything .... you're not far off a finished project  :cartwheel:



Hi thanks for that, it has been a long project ,but i think it will be worth it .I have been thinking about also making the elephant boiler to go with it, and also the  Hirst corn grinding set up but at the moment it is just the engine. I have investigated using proper miniature bricks rarther than wallpaper, but as i will be transporting this around it needs to be quite sturdy......we shall see...........!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 15, 2017, 01:39:51 AM
more work on the finishing and painting the parts. One of the things you find when painting with the matt grey etch primer are the flaws in the surfaces !! however this does mean you can rework the parts with filing and fillers !! i have been using Brummer Stopping as this is pre mixed and very quick drying and is not affected by paint. I found the bearing block ! after making the new parts i went to the soldering heatproof pad and it was sitting there looking very smug!! I have also extended the height of the old 20's drilling machine to be able to reach over the top of the 'A' frames
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 15, 2017, 01:54:18 AM
Looking great! And now that the shop gnomes returned the bearing, you have a spare. To use it up, you need to build another copy of this wonderful engine!!


 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 15, 2017, 02:10:13 AM
thanks i could offer a kit (just one) wth a load of bar stock and just this part to one lucky purchaser !! a bit like a set of Hepplewhite restored chairs..........using one original chair that has been taken apart and one piece incorporated into the other 12 !! ...actuallyi have quite a few "spare" parts ready to be gold plated and turned into jewellery !! some lucky friends..........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 16, 2017, 05:01:38 PM
Three new photos from Beeleigh mill (courtesy of BMRG )  showing the Air pump valves. I thought these may have been Hippopotamus hide flap valves ! but they are metal to metal flap valves as can be seen in the pics. They are still in working order and there was no packing in the pump valve apparantly, just using the water condensate to seal it with the vacuum suction.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 16, 2017, 06:04:28 PM
Great to see that kind of detail. I just went and looked up the restoration group, they have a nice website with details on the mill:
    http://beeleighmill.co.uk/


 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 21, 2017, 01:12:18 AM
more finishing and painting.........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Ye-Ole Steam Dude on July 21, 2017, 01:43:24 AM
The paint work really look good Steam Guy Willy and that is a very nice website.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 22, 2017, 02:31:50 AM
more work on the cylinder table ,cutting out the metal with a drill, then carving out to size with a broach and finishing with files. Also attaching the bearing trunnions with square headed bolts, these are ordinary 10BA hex bolts filed to shape....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 26, 2017, 02:34:55 AM
more finishing and painting...............
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 26, 2017, 02:57:07 AM
Wow, what a change! Looking great. Are these the original colors?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 26, 2017, 01:22:56 PM
Hi Chris, Unfortunately there is no indication of the original colours as after the mill burnt down in 1875 it was left open to the elements for 100 odd years until a new roof was erected over it.!! So it is in its very rusty condition apart from a coating of red oxide on the standards. They thought they found some indication of white paint but i don't think this would have been original.  Yes it is looking ok but the paint has now concealed all the actually construction details and i may be getting requests for the "Castings" !!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Ye-Ole Steam Dude on July 26, 2017, 02:28:39 PM
The paint seems to me to highlight the details better and that is good. I just put the first coat of primer on my engine, so I am following in your footsteps.

Thomas
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 29, 2017, 02:01:18 PM
A bit more work on the sweep rod........making the cotters and straps.........So these are quite small and they should have square holes cut int the thickness of the metal ,what i thought i could do was to to cheat and just drill a hole through both parts and insert the cotters and straps one piece of metal, from both sides ,i did try this but may end up doing it properly........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 02, 2017, 02:01:51 PM
Still making and refinishing the parts prior to painting......a slight diversion talking about beam engine columns. the entasis is the slight bowing of the column that is made so that when viewed from afar the column looks as though it is parallel rather than slightly narrowing in the middle. so the conchordial projection is achieved by making the column usually 8 times higher than the bottom diameter ,( roughly the length of your foot to your height) A drawing is made by starting with the height of the column drawn with a right angle length the same. the height is then divided into 8 and 8 lines drawn thus , as in the drawing.  The lines drawn are longer as they reach the top of the column. A measurement of half the bottom diameter is then drawn from the centre line and where these intersect is the diameters of the column at the places at right angles to the centre line. This may sound a bit long winded but perusal of the drawing so make this clear. Fluted columns always incorporated entasis and the grooves at the top and bottom were semi circular. The curves width to the ridge width was always 1/5 to 4/5ths. And all columns had 24 flutes and were worked out with grooves 12 degrees and ridges 3 degrees......So making these columns in stone and wood were quite strait forward but truing to do this with CNC might be quite difficult as mentioned by others on this site. This diatribe is now finished and i hope it has been helpful !! With the Bridewell beam engine and also the engine in the jan Leno museum the fluted column has been strengthened by the addition of the curved bracing casting as the column was not strong enough to with stand the forces from the engine and flywheel.The repair can be seen on the gothic beam bearing casting. This column is actually 1 to 5 actually.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on August 02, 2017, 02:38:28 PM
What a clever way to lay out the shape! Similar to the way the camber was worked out for a ship's deck, extended lines from chords of a circle.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 02, 2017, 09:09:03 PM
hi Chris, I did not know that about ships decks, and i have always wondered where you start from when you design a ship/boat, lots of secrets therein i bet !!. More work on the engine and it looks like this so far.......still lots to do though, and i will be taking it to Beeleigh on Sunday the 10th of September as part of the national Heritage open Days scheme, Hopefully it will be in steam !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on August 02, 2017, 11:26:44 PM
Very nice Willy.  :ThumbsUp: As I've said before, it's especially interesting with all of the related history.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Roger B on August 05, 2017, 04:28:47 PM
Good progress and as Carl says all the historic details add to the interest  :ThumbsUp:  :ThumbsUp:  :wine1: 
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 07, 2017, 12:47:41 AM
Thanks for the comments, and the cylinder block is now finished and painted, so now just the flywheel to complete.....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 10, 2017, 02:13:51 AM
more work on the flywheel......I have lost count how many parts there are in total about 60 i should say.....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 13, 2017, 12:55:16 AM
the rear of the flywheel with the first undercoat painted....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on August 13, 2017, 01:11:39 AM
Looking incredible!!


 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on August 13, 2017, 01:14:48 AM
Very nice Willy, this continues to be be an amazing project.


Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Fowellbox on August 13, 2017, 11:48:22 AM
Aah, Maldon, one of my favourite places where I learnt how to sail. I've not heard of this engine so time for a Google!
Brian
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 13, 2017, 12:53:59 PM
Hi Brian, i learnt to sail at Brightlingsea a bit further away...... There is an open w/e on 9th 10th september ,part of the Heritage open day thing, however parking is very limited so they suggest parking at Langdon steam museum and swimming across the river, sorry walking !! I will be taking the engine there with a small boiler to power it up!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Fowellbox on August 13, 2017, 01:20:20 PM
Thanks for the information but, unfortunately (in a way) I shall be at Forncett Model Engineering Day.
Brian
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 13, 2017, 02:07:52 PM
Hi, Brian the Model engineering day is on the 1st of October this year and i will be there as well ,Have you got the dates mixed up ??see you there...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Fowellbox on August 13, 2017, 03:26:56 PM
Sorry about that, yes the Forncett day is Oct 1st and I'll be there. I got mixed up with a holiday cruise down the Thames from Oxford to London bridge and then on to Greenwich!
See you at Forncett, I'll be upstairs with the static displays (and the tearoom).
Brian
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 16, 2017, 03:02:35 PM
The last part on the flywheel is the top part of the spokes with the complicated cavetto inside curved moulding bit. as this is quite small i thought i would have a go, with help, to 3Dprint it as it is a cosmetic detail and all the curves blend into one another. This was computed with the 'blender' program ...surprise surprise ' !! and this is the sort of result so far...So will see what happens ???
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on August 16, 2017, 03:35:11 PM
Nice detail - up till now, YOU have been the 3D printer!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 16, 2017, 08:20:54 PM
So I suppose we are all 3D printers actually and we could have those initials after our names   ..Mr Bailey TDPA  !! I have got the items now and will try them out later on ........Also got some taps and dies at a boot sale and there are some 'taps'  that i have not seen before ....the M8 has a squarish unfluted thread on it and the 2BA has a triangularity cross section, they don't look as though they could cut a thread but maybe just squeeze a thread in something soft ??  also there is an 8mm reamer and an 8.015 reamer.? Is this to allow a piece of 8mm rod to go through the reamed hole rather the using a turned down piece of 8mm rod to pass through a just 8mm reamed hole ??  any ideas from the cognicenty amongst us.!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Bluechip on August 16, 2017, 08:48:44 PM
They are forming taps, as you say, for soft materials.

Years ago we used them at work, often on sheet ally or occasionally copper.

Hole punched by a sort of centre punch, then one of those sent through.

Always seemed a bit crude to me but it did the job.

Dave

Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on August 16, 2017, 11:34:00 PM
So I suppose we are all 3D printers actually ...

I hope not to offend anyone...but I couldn't get this out of my mind...

3D printers add material...we remove it.  ;D

BTW I got a LulzBot-Mini a couple of weeks ago. Much fun and very useful.
The forum gave me loads of ideas...tool holders, prototyping, jigs, part holders, etc.
So you all are to blame.  ;D
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 17, 2017, 12:01:26 AM
Hi Dave, i thought that might have been so,   so are there tables to tell you what size of drill to use for different  metals ? i have never seen any !! So i have made one of the end parts and having added material to make the part i have removed some by file, and sanded it to fit, I have painted it with undercoat and it sort of seems to have worked. This was designed on the 'Blenda" cad thingy btw.
 
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 18, 2017, 12:27:54 PM
More end pieces fitted and partly painted up to see how it looks.......so getting there. I don't know how long these pieces will last before they biodegrade back into oil, trees, nitrogen, carbon  etc etc !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Fowellbox on August 18, 2017, 01:39:50 PM
They are forming taps, as you say, for soft materials.

Years ago we used them at work, often on sheet ally or occasionally copper.

Hole punched by a sort of centre punch, then one of those sent through.

Always seemed a bit crude to me but it did the job.

Dave

Regarding fluteless taps, I found this. https://www.avontapdie.co.uk/tapping-drill-sizes
There is a table of tapping sizes towards the bottom.
Brian
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 19, 2017, 01:04:32 AM
The flywheel is finished and i have started to paint it .this is the back with the first coat.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Ye-Ole Steam Dude on August 19, 2017, 01:16:44 AM

Looks really good Willy. Looking forward to see the completed engine.

Thomas
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 20, 2017, 05:29:37 PM
The flywheel is now finished and the engine partly assembled......Also some pics from Beeleigh showing the Boiler feed pump dismantled
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on August 20, 2017, 09:06:06 PM
That is looking great with the paint on, amazing how it changes the look, and makes the shapes pop.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: zeeprogrammer on August 20, 2017, 11:20:49 PM
Wow. That's really come a long way.
Fantastic trip.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 31, 2017, 02:38:37 AM
The governor linkages have been made and also the boiler feed pump so just a few more parts to make...again...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: gbritnell on August 31, 2017, 11:54:45 AM
What an elegant looking engine! I really like the color.
gbritnell
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 31, 2017, 12:29:25 PM
What an elegant looking engine! I really like the color.

The colour is   ' Old tin off the shelf green'  It does not have a label so i don't know the exact shade !!! also the computer decides the shade in the final analysis !!!     thanks for the comments end not long now to completion.........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 31, 2017, 11:31:52 PM
The governor linkages now complete.....soon be ready for final assembly
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Ye-Ole Steam Dude on September 01, 2017, 01:27:05 AM

Willy it sure is coming together nicely.

Thomas
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on September 01, 2017, 01:32:48 AM
Beautiful Mr. Willy!

I'm enjoying seeing it all come together.




Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 03, 2017, 10:39:44 PM
The latest assembly pics.... the boiler feed pump shaft has been fitted and the counter weight on the lower valve shaft.   
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 05, 2017, 11:38:35 PM
starting to all come together with all the square headed bolts in place. because the bolts do not have washers the paint is suffering a bit in places
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on September 05, 2017, 11:39:45 PM
Very nice! Great to see it all coming together!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Dave Otto on September 06, 2017, 01:14:06 AM
Looking very nice!


Dave
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 07, 2017, 03:03:33 AM
More work on the sweep rod making the proper jib and cotters. I make them from rod rather than plate as it is easier to hold in the vice, also the governor is connected up.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on September 07, 2017, 04:09:30 AM
Nice bits of fine file work there, well done!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on September 07, 2017, 06:17:29 AM
".....I have here a fine set of 10X magnifiers, fine set. Come on now, someone can certainly use these!"

Willy: "Me! Me! I'm gonna make some very tiny parts......."

Wow!! Your work just continues to amaze!

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 08, 2017, 03:19:47 AM
The engine is now all back together with all its parts !! It does squeak a bit though and it will need some fitting to get it all running sweetly again and run under steam. It will be at Beeleigh Mill ,Maldon Essex on Saturday for the annual Heritage Open Weekend. It will also be at Forncett steam museum on the steam up and model engineers day, There will be quite a few of the local MEM people there and it will be good to meet up again. Just one picture at the mo as it is 3.20 AM and i need my beauty sleep !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on September 08, 2017, 04:34:43 AM
Wow, that's much more ornate and beautiful than I had imagined!!  :P

Beautiful.

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: sco on September 08, 2017, 07:52:45 AM
Looking forward to seeing it in the metal at Forncett Willy!

Simon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on September 08, 2017, 09:15:39 AM
The engine is a beaut! Looking forward to seeing it run. Its been great watching it all come together!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Ye-Ole Steam Dude on September 08, 2017, 09:52:23 AM

Great job Willy, really is an eye-catching engine.

Thomas
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 16, 2017, 02:44:24 PM
So, the Heritage W/E was fun with lots of visitors in attendance and much interest in the full size engine and the model !!!A few pics of the event and the three models on display will be at the Forncett Museum  model engineers day on 1st October.......They have managed to take apart quite a few of the components and one pic of the HP cylinder cover shows the protruding stubbs for the gland bolts. These look like brand new polished stainless steel items but are if fact the 1830 original pins. there are no machining marks on them and they are almost "polished" to a bright finish. !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 21, 2017, 01:46:46 AM


Beeleigh mill model beam engine.


So here is the engine finished and running on compressed air......     A few adjustments need to be made however This and my other engines will be at Forncett on the first of October !!! See the rest of the gang there ......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Ye-Ole Steam Dude on September 21, 2017, 01:54:59 AM
Willy, I just love your engine, looks great and runs great. Love all the action and movement. Great job.

Thomas
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on September 21, 2017, 02:05:34 AM
Fantastic to see it going! Congratulations!!


 :cheers:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on September 21, 2017, 02:47:56 AM
Excellent!!   :pinkelephant: :whoohoo: :cartwheel:

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: deltatango on September 21, 2017, 08:12:14 AM
The engine looks great! I'm really looking forward to seeing it in the metal at Forncett.

David
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: sco on September 21, 2017, 08:14:44 AM
The engine looks great! I'm really looking forward to seeing it in the metal at Forncett.

David

Me too - see you soon Willy!

Simon.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Admiral_dk on September 21, 2017, 11:50:55 AM
Congratulations on a fine runner and a nice scalemodel after all your work  :praise2:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Jo on September 21, 2017, 12:19:28 PM
 8) well done Willy,

Jo
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 21, 2017, 02:34:42 PM
Thanks for all the kind comments, It was great fun making this engine and also being involved in a small way with the restoration, Also thanks to Clare ,my satnav and photography buddy for putting up with all my questions and comments about modern IT stuff !!. The next project may be the Elephant boiler and the Corn grinding 'Hurst' to go with it. I am also exploring the possibility of making the stand for the model with the scale bricks that one can purchase.... The next beam engine i would like to make is the Woolf compound by J.E.Hall that is ensconced in the Science museum... Also i would like to make one of the engines that was in the local sewage pumping station here in Norridge The only item remaining in the BLDG is one of the spiral staircases !!...There is one photo and lots of drawings in the local archives for these engines. So we shall see...........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 22, 2017, 01:26:06 AM


Beeleigh Mill model working under steam

So the engine is now working under steam after more adjustments here and there,! one of the advantages with steam is that you can see where the leaks are. So more tidying up and assembling the condenser and air pump. The governor also needs connecting up and unfortunately i have lost one of the bevel gears so it won't be revolving,  And just a week to go for Forncett...........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on September 22, 2017, 01:46:37 AM
Wonderful to see it under steam, beautifully done!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: MJM460 on September 22, 2017, 08:49:56 AM
Hi Willy, a beautiful job and great to see it running on steam, just as it should.

MJM460
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: kvom on September 22, 2017, 02:03:54 PM
How slow can it run?  When one sees videos of restored beam engines the beams have a very "majestic" motion.  It would be nice to see this model running at about half the speed in your video.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 22, 2017, 02:20:50 PM
How slow can it run?  When one sees videos of restored beam engines the beams have a very "majestic" motion.  It would be nice to see this model running at about half the speed in your video.

Hi Kvom ,yes i know what you mean  , I shall try and see how slow it could go, at the moment it is between 60 and 80 rpm........ :thinking: It might need a heavier flywheel to keep the momentum though. I could mill out the rear of said flywheel and fill it with lead !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on September 22, 2017, 03:00:29 PM
On the twin beam engine I did, the way I got it to run slower was to fit a needle valve in the steam line close to the cyklinders and adjust the speed with that rather than changing the flow back at the boiler or compressor with the pressure regulator. That way it had higher pressure but lower flow at the cylinder, and would let me dial the speed down a lot more. At least, thats the explanation I wound up with, it did work though. That one had a small light flywheel, which at the low speeds was pretty much irrelevant. That was on a twin cylinder with 90 degree offset cranks, so no dead spots to have to carry through on. In your engine, the heavier flywheel would help with that.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 22, 2017, 03:08:33 PM
Hi Chris ,i do have a needle valve on the inlet to the steam jacket so that might have the effect of wiredrawing the steam to slow it down ???????
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on September 22, 2017, 03:12:32 PM
Hi Chris ,i do have a needle valve on the inlet to the steam jacket so that might have the effect of wiredrawing the steam to slow it down ???????
Quite possible, it worked on mine, but that one is not a compound like yours. If it's already there, worth a try! At worst, you get to steam it up and watch it go again, which is always fun anyway.   ^-^
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 24, 2017, 12:52:09 AM
Well ,i have managed to slow it down but the needle valve is a bit tricky to get exactly right !! cleaning up some of the parts ...the beam bearings have square bolts just one per stud and they are just adjusted and then have a plate filed to keep them from turning. The weight of the beam and sweep rod and pistons keeps it from needing too much pressure to keep it in place.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on September 24, 2017, 01:29:13 AM
Those retainer plates are a new one to me, clever.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 24, 2017, 02:17:19 PM
Those retainer plates are a new one to me, clever.


Here are the real ones, just dropped in place with no fixings !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on September 24, 2017, 02:53:37 PM
Very interesting - on the original ones you can see how the bolts at both ends could be retained at any 45 degree increment. Clever stuff!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 25, 2017, 12:52:01 AM
[quote author=crueby
Very interesting - on the original ones you can see how the bolts at both ends could be retained at any 45 degree increment. Clever stuff!


Yes and i have not seen these on other engines on its sister engine at the Ramm brewery they have double nuts but this engine is still running unlike the Beeleigh engine that burnt down in 1875 and has been untouched since then, A few more pics of the restoration progress with removal of the pistons. Also a drawing of the piston construction....The piston is tapered at the bottom inversely and the piston was slid down the piston rod and a nut followed it and tightened up from above.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Ramon on September 29, 2017, 10:25:59 PM
Hello Willy,

Having not been on here for far too long I've just caught up with the fact you now have your engine finished. That's a great result all round and a lovely runner to boot. Nothing beats that after so much effort so I expect you are well pleased with the outcome.

I'll look forwards to catching up with you on Sunday and seeing the engine run for real.

Regards for now - Ramon (Tug)
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on September 30, 2017, 01:27:19 AM
Hi Tug thanks for that just a few little jobs to do before sunday.............will be good to catch up again on sunday ...cheers
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 09, 2017, 01:55:30 PM
Hi, All   good fun at Forncett last week and i will be posting photos 8 at a time soon. Also News from Beeleigh....They have removed the pistons and have started to take them apart and this reviews the construction that i have not seen before!! So these are contemporaneous with the build about 1810-30, they do not have an exact date for the engine. The pistons have two sets of four iron 1/4 shaped hoops that have brass wedges to expand them into the bore. it looks like there is a spring behind these rings to expand them into the bore. They are all in a remarkably good state of preservation and even have a polished look to them, from the reflections of the table. So to Forncett, i took  the Beeleigh engine and attempted to run it on air....but after about half an hour it started to squeek and the stopped running as if it had seized up !! the motion was then very tight and would not run again and it was suggested i should have had an oiler in the air line ! Also as it is a compound it would work quite differently from steam as it would with air......any way good to see the other MEM men there. and here are the picks......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Steamer5 on October 09, 2017, 04:30:16 PM
Hi Willy,
 That's a shame about the engine, I hope theres no damage, I guess an oiler is in the pipeline.

Thanks for the photos of the piston, those old guys were pretty cunning! Would love to see some more pictures when you guys get it apart some more

Cheers Kerrin
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 09, 2017, 05:04:46 PM
Hi Kerrin , an oiler in the pipeline !! yup diffinately.....More pics.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 10, 2017, 08:28:04 PM
more pics........Also at the local Mans Shed we have a very worn used Southbend lathe  9" ,Model A , bed length 3 1/2 feet  Gearbox plate No 4447....bed number 118877  with the cross slide feed screw  3/8 " it needs a new one of these with the nut which is also worn......are spares available and any info about how to remove the feed screw as it has a powered cross slide gear wheel attached. Any info about this would be very useful ..........Thanks.......
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on October 10, 2017, 09:33:53 PM
Willy,
Go here for lots of info, links, etc. for South Bend Lathes:

http://www.practicalmachinist.com/vb/south-bend-lathes/

If that doesn't yield the information you need then contact me directly. I know the 9" family pretty well.

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 11, 2017, 01:21:45 AM
Hi, Pete thanks for this , I shall look it up and it looks to be really helpful......
Willy.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 12, 2017, 01:28:37 AM
Hi Pete, i cannot log into this site as they have told me that my email address is already in use ??? I wanted to know how to remove the cross slide feed screw and is it possible to get a replacement feed screw and nut , possibly in the UK ?? if you can help that would be great. Also the serial number on the bed is  118877 So this seems a bit unusual ?? This screw has a gear attached that stops it being extracted ? Thanks

willy
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: deltatango on October 12, 2017, 04:56:45 AM
Hi Willy,
If my Hercus is as good a clone as I think it is the pinion that is machined at the near end of the cross-slide screw doesn't stop it being removed. Just behind the boss that has the fiducial line for the cross-slide index there should be a small hole on the underside.  This is for a pin spanner to unscrew the sleeve - the feed screw should come with it. I'll PM you with more details.
DT
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: deltatango on October 12, 2017, 06:28:16 AM
Willy, Just remembered that I had a scrap saddle at the back of a cupboard so I took a couple of pictures. I don't have one from a Model A with a gear but they come apart the same way. This one doesn't have a hole for a C spanner, might have to use a strap wrench
DT
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 12, 2017, 12:49:35 PM
Hi Pete thanks for that....there is a hole ,but thought it might be an oiling hole , we did try to move it with Mole grips but did not want to force it too much, will try again ....a right hand thread presumably ?   I think my next engine will be the Boulton/Bertinat triple expansion engine as i can get the castings locally from a club member ..about 27 castings in all complete with condenser !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: deltatango on October 18, 2017, 12:21:19 PM
Yes definitely right hand in the ones I have here. Sorry about the slow response, I missed this reply for a while, "notify" hasn't worked for me for months.
DT
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 18, 2017, 03:38:51 PM
Hi DT thanks for that and yes it has now been move the 2nd time in 70 years.......The Beeleigh engine is now being exhibited at the Lowestoft Model Engineers exhibition this W/E   LOWMEX  And after this i will be stripping it down again after readjusting the valves as it is being filmed by the Essex Film Group that is documenting the Restoration at the mill. They will be filming the engine running under steam and then i will be working on some of the parts for them to complete my part talking about and making this fine engine. I have now two new projects......A freelance Mill engine using the HP cylinder from a Stuart turner triple expansion engine  ! this will be made up as i go along !! And also i have the castings and drawing for the Boulton/Bertinat/Bailey triple expansion engine.....This is a quite large engine with 43 gunmetal castings....and 3 lots of opportunity to trip up with !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on October 18, 2017, 04:03:20 PM
Nice set of castings - keep the door locked or Jo might wander off with them...!  :Lol:

Hope we can get a view of the film when it is done, sounds very interesting. 
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Jo on October 18, 2017, 04:45:19 PM
I don't have a set of those  :thinking:  I wonder if they are a bit big :headscratch:  Would I want to make one  :noidea:

It might be best if I borrow them to check   ;)

Jo
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 19, 2017, 01:48:37 AM
Hi, Chris, The film is about the restoration of the Mill and i am just a part of this . The film won't be ready for some time  perhaps a few years ?? and as it is there own property it won't be available until it is finished and working, possibly with an electric motor. !!
Hi Jo, i have bought them from a fellow colleage from our club and they were quite reasonable , I have always wanted to build a triple and this seamed like a lovely engine. I have bean having second thoughts about it though and will get the write up from the 1985 Model Engineer, when Mr Betinat made one .
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 19, 2017, 02:16:57 AM
Willy,
Go here for lots of info, links, etc. for South Bend Lathes:

http://www.practicalmachinist.com/vb/south-bend-lathes/

If that doesn't yield the information you need then contact me directly. I know the 9" family pretty well.

Pete

Hi Pete i sent you a message but could not attach photos so here they are   Serial No 118877   ????  and gearbox No is  4447
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 19, 2017, 02:24:48 AM
I was going to start a new thread/post on the Freelance Mill engine but don't quite know how ?? so here are a few more photos so far...... If someone could let me know that would be cool............Thanks
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Kim on October 19, 2017, 05:34:57 AM
I was going to start a new thread/post on the Freelance Mill engine but don't quite know how ?? so here are a few more photos so far...... If someone could let me know that would be cool............Thanks

Willy,
To start a new topic all you need to do is:

1) Go to the sub-forum where you want to start your new thread.
2) Click on the "New Topic" button circled in Red in the picture here.
(http://listerengine.com/coppermine/albums/userpics/10008/Misc-NewTopicButton.jpg)

Then give your topic a name, and type your post just like any other reply.

Good luck!
Kim
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 19, 2017, 02:34:36 PM
OK thanks Kim so this is now on   Freelance Mill Engine  !!! And the Boulton Triple is on hold for the time being till i pluck up the courage to start it !!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 23, 2017, 03:31:31 PM
More Photos from the restoration work on Beeleigh mill...the construction of the piston "rings" with round springs and square spacers.....
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on October 23, 2017, 03:35:16 PM
Thats an interesting way they did it!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on October 31, 2017, 03:10:46 PM
More pics of the LP piston at the mill  quite a lot of corrosion on the brass wedges  and they are looking to make new springs and spacers for them.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 18, 2017, 01:27:50 AM
I have been trying to get the engine to work again after it seized up at Forncett and have taken it apart to find a nut had fallen into the LP steam chest and was fouling the valve. however this was an intermittent fault so not immediately apparent.It seems to have weakened the eccentric to valve cross shaft and it has broken so i have to make a new one of those and then retime everything to have another go at it under steam !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 19, 2017, 03:05:11 PM
Have now made a new shaft for the transfer valve mechanism... the original  .125' shaft was turned down to  .069" which is why it broke. I fave filled the bores out to about .115 and the new shaft turned to match. the shaft is now back in position and should give no more trouble...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 20, 2017, 02:05:38 AM
I connected everything up again and found that the locktite had failed on two of the arms so took everything apart and pinned them in place after using locktite again a new photo showing the balance weight in position..Also some of my homemade nut runners for these small 10  and 12 BA nuts and bolts. With the twelve BA sizes the nuts are different A/F to the blots.!! I do not understand why there is a counterweight as the valve linkage is driven from the eccentric which the weight has no control over ? perhaps there is some predetermined  inbuilt play in the linkage ?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 10, 2017, 01:52:45 PM
More pictures of the restoration at Beeleigh mill ..They have now removed the HP steam chest and have to replace the historically broken off bolts. I wish that all this had been done before i started on the model as it would have been easier to see how everything was actually constructed and put together !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on December 10, 2017, 01:55:45 PM
Really interesting to see the inside parts!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 10, 2017, 02:36:08 PM
Really interesting to see the inside parts!
[/quote]

Hi, yes ,And this is what i did on the model ...just two holes rather than the quite large slot at the bottom.!!!

Willy.........
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 18, 2018, 05:25:59 PM
More work on the engine at Beeleigh... they have removed the air pump casting and it has this butterfly at the bottom that lets the water/ air  travel from the condenser to the air pump so the restoration is well under way...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 18, 2018, 05:29:15 PM
Neat!

Hope when it is all restored that you/they will publish a book, with full plans, about the mill and its engine!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on February 18, 2018, 05:36:15 PM
There is a film being made by the local film group ,but there is still lots to do and i don't know about getting it into steam as they cannot use the original elephant boiler. I have all my own drawings that will need modifying somewhat  as more of the engine is revealed !
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on February 18, 2018, 05:39:46 PM
There is a film being made by the local film group ,but there is still lots to do and i don't know about getting it into steam as they cannot use the original elephant boiler. I have all my own drawings that will need modifying somewhat  as more of the engine is revealed !

It would not be as efficient since it is a compound engine, but it could be run off a construction-site style air compressor. They use one to move the Lombards around the barn for maintanence when it is not worth firing the boiler. Hope you can get your plans published when it is all done!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on March 08, 2018, 01:21:03 AM
Hi Chris , good idea with the compressor i will suggest it to them...more removal of parts on the restoration side... and intriguing that there is still bright steel on some of the parts...the ball end of the lever on the valve cross shaft.
!! The part on the red background is the jet condenser valve with thick lead gasket.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 11, 2018, 02:32:36 PM
More restoration work on the engine ...They have taken the crossheads apart and have found quite substantial pitting and damage to the brasses...however they are 180 years old..
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 12, 2018, 02:02:23 PM
More pics of the straps undergoing the restoration work ....the dummy wooden piston will be used as a makeshift hone to investigate the cylinder bores...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 12, 2018, 02:04:55 PM
Great to see the restoration is continuing!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 24, 2018, 11:45:35 PM
More restoration work.. they have cleaned up the HP crosshead and also discovered that the piston rod boss was separate to the journal shaft. This was to provide a bit of lateral movement to align the piston rod to centralise with the cylinder....cunning stuff
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 29, 2018, 11:23:07 PM
Restoration continuing with honing the HP cylinder and Looking at the bearing block between the flywheel and the hurst, This bearing has a lower insert part of brass but the other top part is just cast iron and this part has the mating surfaces cast i such a way as to only slide in one way,  the bearing surfaces look to be in tolerably good condition. Also the cylinders after being honed are looking in good condition,
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 30, 2018, 12:29:05 AM
Very interesting to see the restoration photos, thanks!
Terminology question: what is a 'hurst'?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 30, 2018, 02:52:45 AM
Hi Chris, the hurst is the local name for the corn milling machinery....Here are some pics. The bearing on the left of the last pic by the vertical bevel gear is the one in the last post
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 30, 2018, 03:00:11 AM
Quite a mechanism, those gears look to be in pretty decent shape. Do you have an overall diagram of the whole mill?


 :popcorn:
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on July 31, 2018, 02:38:48 AM
Hi Chris, I will get some pics and drawings together soon in the meantime here are a few.......Plan view....3 D image ..Boiler firing pit and rear of the building..

Willy
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on July 31, 2018, 03:34:39 AM
Fantastic. You and John need to collaborate on a diorama.


What does the steam engine drive and what do the water wheels drive? Are both wheels on same shaft?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 18, 2018, 10:54:33 PM
More restoration on the Beeleigh mill ...the pistons and  cylinder covers have been cleaned up and found to be in really serviceable condition. The covers and the stuffing box flange have a separate brass bush that may be found to be remade to cater for the reduced size of piston rod as it was skimmed down, being a bit rusty. so assembly soon...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on November 18, 2018, 11:08:23 PM
Great to see it progressing, those parts are in remarkable condition.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: 10KPete on November 19, 2018, 02:29:25 AM
That's some really nice iron to resist rusting like that!  I don't think I've ever seen iron that old, in a wet environment, that looked that good. The oil and grease used must have been wonderful....

Pete
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: Ye-Ole Steam Dude on November 19, 2018, 12:51:06 PM
Hello Willy,

The brick on that building is beautiful and looks to be in good condition.

Have a great day,
Thomas
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on November 25, 2018, 04:32:54 PM
Thanks for the comments.....the pistons are now inserted and the cylinder covers cleaned up.  there are new cylinders head bolts made and in place and you can see the skimmed piston rods all nice and shiny !!  Still lots to do and a decision about the painting is still to be made.!! Also some of the carburised gland packing from the 1875 fire !!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on November 25, 2018, 07:09:07 PM
Glad they are making progress, and those are the biggest square head bolts I've ever seen! Do they have a guestimate on when the restoration will be complete enough to turn the engine over, even if its by an outside electric motor? That will be a very happy day!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on December 16, 2018, 04:41:07 PM
More work on the restoration.....they are cleaning up the HP steam chest.....removing 170 year old braided packing....and looking to mend the  main steam valve and the governor butterfly valve that broke on disassembly  !!??  !!!
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on December 16, 2018, 05:39:33 PM
Great to see it being saved!  I take it you are taking more detail measurements as more comes apart, for the plans and history book you are going to write?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 13, 2019, 04:08:48 PM
Hi Chris ,  yes that is being done slowly .....They have now affixed an electric motor Via a vehicle road wheel to turn the flywheel. This operates with some success although there are some tight spots. Looking forward to some cosmetic work being done !!! Also an image of the mill they have made !
Willy.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on January 13, 2019, 05:00:27 PM
So it went from water power to steam at some point?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on January 13, 2019, 05:22:34 PM
Hi Chris yes ,it started off with water quite some time ago and then had the engine installed with its own set of stones about 1840. The mill then burnt down in 1875 and was never rebuilt....something to do with the Parliamentary corn laws ???

willy
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on April 22, 2019, 02:13:18 PM
They have been doing more restoration work on this engine and it
 now revolves freely using the motor and road wheel on the flywheel. They have also repaired one of the bearing caps that was broken. They glued it together with epoxy resin and then drilled two holes through it and inserted pins and profiled to shape to be almost invisible. At the moment they are continuing to restore the corn grinding Hirst to complete the restoration although it will be some time before and if they can run the engine on steam!!

willy
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 17, 2019, 04:53:50 PM
there has been more work recently on the Beeleigh restoration...making gaskets for the steam chests and cylinder heads  also putting rope gaskets around the lower exhaust ports to the condenser.
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 17, 2019, 04:59:44 PM
They have also made a trough st stop water getting into the flywheel pit to keep the flywheel dry. also the condenser jet valve mechanism has been restored...
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: crueby on August 17, 2019, 06:49:23 PM
Nice to see them copying your model in large scale...  :Jester:




Looks like great progress on the mill, great to see! 




Never seen rope used as gasket, why rope?
Title: Re: The Beeleigh Mill, Woolf compound engine.Maldon, Essex.
Post by: steam guy willy on August 17, 2019, 08:10:31 PM
Hi Chris, Rope ? There is quite a large gap between the exhaust port and the table that connects to the condenser . This does not necessarily have to be so steam tight as the steam has finished most of its work in the cylinders and the condenser has given it a bit of extra 'pull'.. Also the cylinder casting and the entablature casting are not planed and turned exactly flat to give a good mating surface. Also the cylinders have to be fitted and adjusted to line up with the beam so there has to be a bit of Rocking movement to adjust these parameters. Once the cylinder block has been lined up using small wedges to position it, the space can be in filled with a mixture of iron fillings red lead and urine to make a sort of cement !!! I will find some photos and drawings to make it clearer...Some photos showing the gap and also the sheared off bolts before restoration !! Also the two exhaust ports each side of the casting . This was done to even up the asthetics and also the casting process ?? The two pieces of rope are under these ports.

Willy