No rest for the YVG

Hello and welcome to a short first blog update for 2019. Firstly a Happy New Year to all of our readers, we had a really good last 6 months here at the VGR workshop blog and we look forward to a bigger and better 2019 (not 2018 as the Sydney Harbour Bridge tried to tell us a couple of days ago!).

With Mick on holidays and many of the volunteers away on “other duties” over the Christmas / New Year period you would think that there would be nothing much going on at the Victorian Goldfields Railway’s Maldon workshop. Well nothing could be further from the truth! A few staunch volunteers/staff have been sighted cleaning up the Shed and Workshop Compound area while The Young Volunteers Group decided that the holidays were a perfect time to get the VR Blue and Gold applied to our heritage diesel locomotive Y133.

As your blogger has also been AWOL over the holidays I have yet to see either in the flesh or via email the work as it stands but I am reliably informed that it is going very well indeed. Tomorrow will be a real scorcher, way too hot for spray painting as the paint will dry before it hits the metal causing a nasty Orange peel effect but with some cooler days coming up over the weekend the job will hopefully be completed very soon.

Until we get some more up to date pics we will have to settle for more of Riley’s great shots of the progress that was made on the metal work in the weeks leading up to Christmas.

020100

020101.jpg

Above we see some of the work completed in the radiator compartment. This area had seen a lot of water ingress in recent years and the water was trapped in the compartment leading to rust. After the dirt and scale was removed a drain hole was discovered – even old hands at the VGR claimed they had never seen it before!

020104.jpg020102.jpg

More shots of the great work done on the nose. This was particularly difficult work as the front is not flat but has a transition, multiple small changes of angle to get the look. In a brilliant piece of lateral thinking Baz used the recently completed wooden deck of the QR wagon as a sheet metal bending and forming tool! The results speak for themselves.

020105

As ex Overland carriage Tambo looks on we can see some of the work still to be done. The parts of the carbody which are covered by the doors are particularly susceptible to rust while the vibrations of the big 2 Stroke Diesel engine can cause cracks in other parts of the same parts as well as in the doors. This lot was all stripped back and repaired before the painting began.

Well we did say it would be short! Apologies for the last post which was supposed to go live on Dec 13th as a follow on from the Dec 8th post but for some reason doesn’t seem to have loaded. Also a big shout out to young Riley who apparently came off second best after trying to drop punt a Locomotice Brake Block, get well soon mate!

With J549 scheduled to run services for the next week or so there have been really good passenger numbers on our trains over the holidays with plenty of families enjoying today’s trip. Get over to vgr.com.au to grab your seat or better still hang out until February and be part of history as the refurbished Y133 hits the rails.

 

Advertisements

Unfinished (and finished) Business

Well folks, another week has flown by and it is time for a further update on works at the Victorian Goldfields Railway’s Maldon workshops. Last time out we featured work on K153 in preparation for her annual boiler inspection. After the post went live we realised that we had made an omission which might have made it difficult for some to follow! We covered Mick drilling out and replacing one stay “between the sheets” and we also covered gun welder Darren working on a stay on the throat plate. Those with a bit of knowledge would have picked that they are not anywhere near each other! That’s right, we did more than one. In the image below we see the Throat Plate stay in the process of being removed. This one almost broke Mick’s hand while he was trying to drill it out – the stay had suffered much corrosion and was far thinner than anticipated and the drill bit jammed on the edge of the cavity created. As one wag commented “you’d be worn too after 78 years”!

131200

Don’t leave on my account…….

While all of the work on K153 was happening there was still time for some other tasks to be done either by those not involved with the K or in the downtime waiting for welders or inspectors to arrive or for Bricks to set. There was light at the end of the shed for QR272 and with everyone heartily sick of the sight of it there were plenty of willing helpers to finish off the job. Below we see some of the crew applying a sump oil finish to the new deck to protect it, using enough for it to drip through to protect the new steel underneath as well.

131201

131202

Once that was done it was time for an active brake test before outshopping. VGR stalwart, tireless volunteer and ex President Paul was on hand to do the honours. After the successful result (which was a relief after the dozens of man hours spent on the brakes) the wagon was hauled out into the Maldon sunshine.  Described as the “greatest achievement of the last 3 months” by one workshop team member clearly happy to see the back of it! All that is left now is a quick coat of paint and stencilling and it can head out on duties with the Civil crew.

131203

Getting there is half the fun

With that job done attention turned back to Y133. With the VGR’s Young Volunteers Group threatening to apply the Blue and Gold straight after Christmas there is no time to lose in finalising the structural repairs. Below we see Baz cutting some more rust out, first inside the car body and then outside.

131204

131205

With that done it was time to start welding in some new material. YVG member Riley was on hand to snap some shots of the work. Below we see the same part of the nose with the new material welded in.

131206

Next time out we will feature a few more of Riley’s shots as the holes are filled with shiny new steel. Thanks to Riley and Mick for extra photos. Keep up the great work guys (and gals)! And remember that the workshop is always looking for active volunteers, if you think you have got something to offer contact Mick.

 

Here To Stay

Hello again and welcome to another VGR Mechanical Blog update. As promised last time out we continue to look at K153 as we prepare for her annual boiler inspection. As we have said previously a Steam Locomotive boiler is a pressure vessel which requires annual certification by a certified boiler inspector. No ticket, no start! K153 was due and as she is currently on loan to the Victorian Goldfields Railway from our friends at Steamrail the inspection is being done at Maldon.

Stay tuned

Following on from last weeks post the leaking stay needed to be replaced before the inspection could take place. In the picture below Mick is in the process of drilling out the old stay.  It is almost done, 7 different drill bits were used starting with a pilot and gradually stepping up to ensure maximum removal of material with minimal chance of damage to the threads in the sheets.03121

 

03122

Above is the view through the mudplug hole looking at the stay from the inside. This space is between the inner and outer firebox sheets, the fireman’s seat is on the other side of the back wall as we are looking at it. This is a small and inaccessible space and is too tight to get the oxy into so Mick invented a “slide chisel” to remove the large dag which would have prevented the stay from being screwed out.

Now to the new stay which is shown below. The standard size thread for a stay is 1″ but they were made in oversizes to fix problems with worn threads. This one has been made 1″ on one end and 1&1/32″ on the other due to one sheet having been oversized in the past. As it was not going to be possible to weld the outside of the stay due to it being only 1.5″ from the frame an old Railway fitters trick was employed – a tapered thread was used on that end of the stay and it was then screwed up tight to prevent leaks.

03123

With the new stay fitted it was time to get on with the rest of the work for the boiler inspection. All boiler fittings need to be removed for inspection, all plugs removed, gauge glasses, basically anything that is to do with the boiler. Below we see some fittings that have been removed and placed on a trolley awaiting their check up.

03124.jpg

Darren’s Back! (again)

Gun contract welder Darren was called back once more to do some of his great work. Again as we have said previously only a certified Boiler welder can do these critical jobs due to paperwork requirements.

03125

Above we see Darren inside the Firebox welding a throat plate stay and below he is back outside under the barrel next to the blowdown valve on the front of the Throat Plate. This required the K to be parked over the pit so access could be gained from underneath. Not a pleasant place to work, cramped, dirty and a bit damp too!

03126

Thanks for all you help!

Monday morning rolled around and the crew assembled ready for the boiler inspection. Warren and Tim made the drive up from Steamrail, Mick and workshop volunteer Pete were on hand along with a handful of others. The first thing that everyone noticed once the shed doors flew open was how tidy the shed looked. A bit too tidy……. Some helpful person had come in on the weekend and decided to “clean up”. Problem was they cleaned up junk, tools and even parts of the loco and piled them up outside for whatever fate awaited them. One of the missing parts was the Blowdown Valve operating link that was required that day for the inspection. It took 4 people (3 paid and 1 volunteer) 4 and a half hours to find the part. So 13.5 hours of PAID labour lost for nothing, It was frustrating to say the least.

03127.jpg

Above we see the offending article and the pile it was discovered in and below Pete in the pit refitting it after the inspection was completed.

03128

Built like a Brick……. Brick Arch?

As we saw last week the Brick Arch was found to be a bit wanting on the structural integrity front and it needed to be rebuilt. Below we see the new bricks being produced in special moulds onsite by our crew.

03129

After all that hard graft the inspection was completed and the crew got stuck into re-fitting all of the removed components. K153 is now ready for another year of Steaming although not for a few months as CFA restrictions prevent the Railway from running the coal burner at this time of the year. With it being such a dry year in Central Victoria the restriction kicked in a bit early this year. We are still able to run J549 as she is an oil burner but this is done under strict conditions with a Fire Patrol following all trains.

Next week we will take a look at some of the other activities which were going on during the last couple of weeks. Thanks for tuning in.

 

All K-K-Class!

Well folks here we are with another update on goings on at the Victorian Goldfields Railway’s Maldon workshop. Last time out we did promise a quick follow on to the last post but due to circumstances beyond our control (ie work) it got delayed. In the time between then and now K153 has been in the shop for repairs after the “season” before she was stripped for her annual boiler inspection.

While this was going on there was work to be finished on QR272 and the Y class diesel to finish off but first we will take a look at the bruised, battered but not beaten K153.

The most important thing that needed to be tackled before the strip down was a weeping stay. Stays are a sort of stud which screws into the firebox inner sheet at one end and the outer sheet at the other and is then welded to prevent water leaking. The stays are vital to the integrity of the firebox and so are monitored very closely. The stays have a hollow centre at each end and if a crack occurs in a stay the crack makes it’s way to the hole where it stops (preventing it from cracking right through the stay) and a tell tale leak develops.

1539831961641

The photo above shows the leaking stay and the tell tale holes in the adjacent items. We will be covering the repairs on this in a bit more detail in the next post as it relates to the Boiler inspection work, for now we will focus on the other “running repairs” that relate directly to the normal wear and tear that goes with operating a Steam loco in service.

271103

Next up was a look inside the firebox itself which revealed that the Brick Arch was failing. Nothing for it but to make some new bricks. Also on the agenda was patching over a burn hole at the edge of the ash pan door casting shown in the image below. Mick is very proud of this weld, he had to stretch it up from below and couldn’t actually see the Arc so it was welded by feel and lots of luck. You could see through the spokes OK to snap the picture but couldn’t reach in that way to weld it.

271105

271104

In the shot above we see a replacement Fire Grate taken from underneath inside the ash pan. The eagle eyed will notice that the rocker arm is shorter than the other(s) so the rocker link had to be removed and modified to suit.

Back to the front and the smoke box baffle doors were found to be thin and bowing. This was the cause of the table plate filling with Ash which had a detrimental effect on performance as well as making a heck of a mess. The stiffer 1/4″ patches in the photo below should do the trick and keep things in line.

271106.jpg

Finally it was up top where vibration and age take their toll just like most parts of a Steam locomotive. The photos below show the steam inlet and drain of the Turbo Generator which sits atop K153’s boiler. The Turbo uses steam to generate electricity and this system replaced the various types of lamps used on early railways such as oil burning lamps. The inlet had blown out the sealant and the drain was well and truly gone!

271108.jpg

While all of this work was taking place on K153 workshop volunteers with a little help from Mick continued work on QR272. Below we see the slag just falling off a decent weld, this was one that went right, a fair few more had to be done over as the 90 year old rust didn’t take too kindly to being brought back to life.

271101

Well that’s a wrap for this post. All this happened a couple of weeks back and then last week it was Boiler Inspection time. We have an action packed post in the making for later this week showing all the action. In the meantime we leave you with workshop volunteer Keith in his bespoke VGR clogs getting “up to speed” with his tasks for the week. He was complaining that the vice was too high and had taken to standing on a couple of bits of 4 by 2 to gain those extra inches. The duct tape straps made all the difference!

Uptospeed

Till next time keep steaming!

 

Back to Black

Hello and welcome to another Blog post. It has been a busy month or so on the Victorian Goldfields Railway and for our Mechanical crew. As usual for this time of the year lots of trains mean lots of work for the workshop as the VGR tries to ring as much out of the Steam locos as possible before the Summer hits with the inevitable fire bans and Diesel running mandated by the local CFA.

The past couple of weeks can probably be best summed up by the photo below;

BIBBlack

Can’t see much eh? That’s because Mick and the rest of the team have spent much of the last couple of weeks inside the smokebox. Not one but 2 of the dark, dirty claustrophobic places. Firstly the K Class required a clean out and no sooner was that done than J549 needed some attention.

The weekend of the 27th and 28th of October was a biggie with Mucklefest, normal services plus a Steamrail Charter to Castlemaine for good measure. In the week leading up loco crews had been reporting poor steam performance on J549 and a Super Heater element was the suspected culprit. Mick was heading to Phillip Island for the Moto GP so a quick inspection was carried out and it was ruled fit for purpose considering the light duties it was to perform over the weekend. Once the fun had subsided and the loco had cooled down a bit it was time to take a deeper look.

In all 5 Superheater element Ball Ends were found to be in need of replacement and another 10 needed lapping and in order to do this 15 elements had to be unbolted and removed from the Smokebox. As we have said before this is a big job as the petticoat and baffle plates have to come out first and the fasteners are ALWAYS corroded to the point that many must be cut off. Once this is done the special VR forged spanner is used to undo the retaining nuts which requires the use of a big hammer in a small space.  Not easy or pleasant. Each element weights in at 45KG and pulling out 15 of them is certainly not a job for lightweights!

BIB04.jpg

BIB03.jpg

You can see in the first of the 2 photos above the damage wrought on the ball ends by the corrosive steam. When J549 was rebuilt a few years back before it’s return to service the VGR had a batch of new Ball Ends made. Recently many have needed to be replaced well ahead of schedule and poor material choice by the contractor is one possibility being examined. However until we can get more made we need to keep using up the stockpile that we have so this work was completed in pretty short time and our hero was ready to go in time for the next weekend’s services.

The keen eyed amongst you may have noticed the QR wagon lurking in the background. The steel work is now all done and workshop volunteer Pete has almost finished the wood work – if he doesn’t burn it first considering the cold mornings and all the trouble it has given him! With the brakes sorted it should be ready for use by the Civil crew very shortly.

Baz has also been busy using his wide variety of skills to great effect fixing the frame on one of the Hi Rail vehicles and shifting all of the hydraulic systems from under the car into one of the side tool boxes where it will be much better protected from the elements as well as stray ballast.

BIB06

While this going on there was a PV exam to be done on 43 BPL, more work on the Y Class Diesel to get it ready for Summer running and a fair bit of work on K153 to prepare her for an upcoming boiler inspection late this month. We’ll cover that in a separate post next week.

In the meantime as the late, great Ms Winehouse would say it’s Back to Black for our hardworking crew. See you next week!

Onwards and Upwards!

Hello and welcome to another VGR Mechanical blog post. September saw a new record for our little blog, both in terms of total visitors and total page views so we must be doing something right. A big thank you to all of you for taking the time to read it.

It has been a busy few weeks for our Railway with School holidays, Seniors Week and and Ales train meaning lots of work for both J549 and K153. Last Wednesday’s train was a double header with the locos hauling 9 cars and north of 400 passengers on the 12.00 train out of Castlemaine. With all of this extra running comes extra work for the workshop crew and just to make things interesting having both of the rostered Steam locos running at the same time severely limits the time available for maintenance! Usually Mick and his team will perform inspections on one loco while the other is running the service – a bit hard to do with both of them on the pointy end of a train!

Still, the show must go on and first on the agenda was a general mechanical inspection of the K. The smoke box was opened up for a thorough clean out as the ash builds up in this area which has a detrimental effect on performance. The shot below shows the extent of the coverage we found.

ash

Then it was into the pit to check underneath her where a couple of little things came to light and were quickly attended to including a loose keeper bolt on the tender. Working on these parts of the loco low down and covered in oil and road grime it is easy to get hurt so all care must be taken but it all needs to be inspected and fixed at regular intervals.

151004

Work also continued on our bogie open wagon QR272 with some serious welding going on as Mick added some new metal to aid frame stiffness before it is returned to traffic. V/Line / VR cut off the truss bars at some point but more recently some well meaning character(s) cut out a lot of rusty metal without considering the stress diagram which weakened the structure. This job was supposed to be finished and the wagon back on the road by End September but the problems with Y133 took priority but with that work complete it is back to this job.

151001
151000
An ongoing project is monitoring flat spots on wheels, carriage wheels in particular. There are numerous flat spots, some need wheel turning, but some are just monitored to make sure they wear away, not tear away. These are on 41 BU.

151006

151007

On the Victorian Goldfields Railway one round trip Maldon > Castlemaine > Maldon is approximately 20 km powering & 20 on the brakes. Fitting new blocks & adjusting is a weekly thing and we probably average 6 blocks a week but all must be inspected – that’s a lot of blocks to check! Rolling stock inspections go deeper than just blocks though. Seeking out little faults before they become big ones is exactly why Mick gets dirty so we maintain a good safety record. On a recent 1 and a half hour inspection of just 4 carriages we found a half broken split cotter in the bogie swing link on Tambo and a loose bogie pivot plate bolt on 80BW. These are some of the weird things that show up and this is why we inspect the carriages twice a week.

Life is never boring in the workshops and a bit of a left fielder this month was the conversion of our new (old) sleeper changer from 2’6″ to 5’3″. This item is on loan from the good folks at Puffing Billy Railway for a tryout (apologies for not mentioning this in the original post). Below Banjo Baz poses with the finished product!

151005

Well that is about all we have time for. Following some feedback a couple of weeks ago your blogger would just like to re-iterate that the sole purpose of this blog is to show both our Members and the Public some of the hard graft that goes into keeping trains running on the rails of the Victorian Goldfields Railway. It IS hard work, it DOES cost money and our crew led by Mick does a brilliant job with limited resources, limited materials and limited time. Money is never spent lightly and when it does need to be spent the crew goes to great lengths to make sure that our Railway gets the best possible value for money. Help is always welcome in both the manpower and financial departments and we hope that this insiders look at goings on in the workshops at Maldon might encourage a few of you, our readers, to dig deep!

And we end with a footnote – a long term issue with J549 was addressed recently. Members of the VGR may have already read this tale in the Fortnightly Notes but for those of you not privy to them here is Mick’s Turbo Charged commentary!

“On occasions, the “in your face plainly obvious” becomes totally forgotten, and this time I am referring to the performance of the headlight on J549. All crews (and some observant night-time passengers) know that the headlight is, at best, dismal. To rectify this issue we at the dirty end of the railway have checked the Turbo Generator, the wiring, the switches, the reflector, the focusing mechanism & the headlight bulb itself, all to no avail. Nothing we did seemed to help, leaving us scratching our heads & contemplating an expensive rebuild utilising the latest electronic technology. Apart from the expense, this would also generate a mountain of paperwork to allow a change of system to be used.

Well the bit that I had overlooked was the electrical load that was being asked of the Turbo Generator, and as the son of an electrician I feel a bit stupid for not remembering this earlier! J549 has thirteen light bulbs. The front & rear headlights are 150 & 100 watts, but only one is energised at a time. The other eleven globes are 40 watt globes, so 40 X 11 + 150 = 590. The Turbo has a maximum output of 500 watts. . . . . anybody else seeing a problem here?

To this end, with some huge help from Workshop regular volunteer Jacob, I have received & started testing two five-watt L.E.D. globes. Some may think we’ve had L.E.D. technology for years and it should be a simple change over, but the issue is that the power supply is low voltage AC and the current is variable, meaning standard bulbs are not suitable for this application.

151002

I now know that relevant bulbs are available and they do handle the variable current. I still need to know if, they handle the heat and they don’t disintegrate from the vibration. So, there are two test bulbs fitted to the J, which saves 70 watts already, and after further testing, we intend to source more bulbs to allow the headlight to access 80% of the Turbo’s output current. I will be very happy if I start hearing comments that the headlight is too bright, but I doubt it. Onwards & upwards folks”

Onwards and Upwards indeed! Till next time we hope your headlight shines bright and illuminates the road ahead!

Getting Ahead

Well here we are after another hectic week (tomorrow is the Day Before Grand Final Day Public Holiday in Victoria) and it’s time for instalment 3 of this meandering tale of goings on in the Victorian Goldfields Railway’s Maldon workshop featuring our hero, Y133.

There has been plenty of action on the railway as it is school holidays with K153 hauling a packed 7 car train on Wednesday but that isn’t the half of it – we’re here to show you the bits that most people don’t see, the effort that goes on keeping things running smoothly on top of the rails. While our passengers have their fun in the sun work is continuing on the inside and outside of Y133, the QN wagon, the NN hopper and a bunch of other little tasks that combine to make the week fly by.

Y133

The shot below is a bit of a refresher showcasing some of the rust and other damage on the nose of the loco.

New6

New9

In the shot above we can see volunteer Damien getting busy grinding the rusty parts of the nose out so some new steel can be welded in place. What no one was expecting was what he would uncover when he cut the bottom of the nose section out – the shot below shows the floor section in front of the radiator with the build up of gunk that Fletcher and the YVG punched out with the hammer. The radiator has had a number of issues over the last few years as we have covered previously and the leaks and build up of grime in this section have rusted out the chequer plate floor which will have to be replaced.

QR3

New14

Meanwhile the Young Volunteers have been continuing their work preparing the body for paint, in the shot below Riley is hard at work with sandblaster in hand cleaning up some of the small parts of the body. For anyone who has never done this work it is an extremely dusty and boring job so kudos to Riley for his continuing enthusiasm for the task.

New8

It’s out!

While all that was going on Mick and Banjo Baz continued to work removing the #3 cylinder head as they chased the coolant leak into the engine. After purchasing the correct tool to undo the Crab Nuts (a Torque Multiplier) for an eye-watering $900 they finally got the troublesome Crustaceans to budge. Throw in another $300 for a new torque wrench to do them up again (the ones we already had weren’t big enough) and it is becoming an expensive leak.

New2

And there it is – Mick (R) and Baz (L) manhandle the circa 55kg head onto the running board. It is great to have Baz’s diesel fitting experience on hand for this job, his skills complement Mick’s really well and this is not a job you would want to entrust to just anyone – mistakes would be very costly here.

After inspecting the components it is hoped that the leak is simply a life expired gasket so after buying a new set (more $$$) and cleaning up it can be refitted and that should be another job done!

Grate Expectations

A couple of other jobs reared their heads while the crew were trying to attend to the Y class – K153 had a cracked firebox grate that needed to be seen to. These grates need to be replaced periodically due to the extreme heat that they endure however this one decided it didn’t need rescuing and jammed itself firmly in place requiring more time than usual to replace.

New13

Not wanting to be left out J549 got in on the act as well with an inspection before running last Wednesday finding a Piston wedge had dropped in the crosshead as shown below. This required Mick to drop everything and build it up and re-profile it during the running day.

New7

Tractor 1, Wheelbarrow Nil

The dulcet tones of the BBC’s Soccer score roundup of the 1970s sprang to mind as we checked the pulse of our long serving workshop wheelbarrow after it’s run in with the Green meanie. Should have been wearing a high viz!

New12

Speaking of Green Meanies, your blogger took time out to speak to workshop volunteer Keith who was busy painting short sections of rail. You could say it was a doorstop interview!

New10

Well after that terrible pun I think it is time to wrap this one up. We’ll be back soon with more fun and games. Your blogger hopes that these posts give you some idea of the hard graft that goes into keeping the VGR on track. The workshop is always looking for a helping hand so if you think you have something to offer please feel free to contact Mick. I’ll leave you with a snap of some of the new materials that just arrived for the QN wagon that we are overhauling for the Civil Branch. Gotta bolt!

New11