Tag Archives: boiler

Boiler tubes (in profusion)!

The tubes are ready to fit…!

After what must have been an epic session, Nigel and his assistants in the southern group of the “Boiler Collective” have now cut, deburred and bent the 600+ tubes for the three boilers we are building.

The pictures below show the extent of this activity, and the bending jigs they made…. (thank you men)!

We first made a trial set by measurement from and comparison to the drawings (yes, yes, I know “never scale from drawings“), we then test fitted these and they were good. So then the team cut the rest using an angle grinder in an adjustable jig. Then cleaned up the ends with a bench-mounted wire wheel, and finally bent them to the appropriate angles using the bender we “pre-calibrated” in the trial run.

EPIC….

A boiler making “Contraption”

More Progress on the Boilers – and a “Contraption”

We now have all the components to commence the “real construction” of the boilers.

Boilerplate and Steel

As you will recall from earlier posts we have drilled the holes in the steam and mud drums, and ordered the plasma cut 3mm plates for the housings from Ashby Welding in Church Crookham, and (after a lot of searching) ordered the 20mm Boiler Plate for the drum ends – which was eventually sourced from Brown MacFarlane in Stoke on Trent with the very capable assistance of  their Account Manager Alan Taylor. So the Landy made another round trip to Hampshire with a good load of steel in the back!

Boiler Plate and Casing Steel

Boiler Plate and Casing Steel

A First Set of Tubes

While in Hampshire Nigel Thomson and I spent a few hours in is workshop making a first set of 5 boiler tubes, so that I could test fit them in the boilers. They all fitted, as the pictures below indicate. So now he and Mark have only 600 or so more to do! (and you can see the plasma-cut end plates from the CAD drawings in an earlier post).

Boiler Drums in Casing

Boiler Drums in Casing

First Tube set in place

First Tube set in place

A Contraption

In order to finally fit the tubes a “tube expander” is fitted into the end of each tube and this is wound into the tube to expand it into the drum, and this secures it in place. This requires that we have a mechanism to reach inside the steam and mud drums to screw the expanders into and out of each tube, and also to drive a countersink bit to clean and de-burr the inside of each of the 1,200 tube holes in the drums. We thought of using a right-angle air ratchet wrench to do this, but having tried this out I decided to opt for a more “traditional” chain-driven tool, that Louise immediately  christened “A Contraption”….

Here are some pictures and a video of The Contraption with some old bloke demonstrating its use, and showing how well it cleaned up the holes in one half of one of the steam drums.

The pictures below show the effectiveness of de-burring the holes on the right-side of this steam drum (and it was quick too)…

Deburred Tube Holes in Steam Drum

Deburred Tube Holes in Steam Drum

What a lot of holes…

We are progressing with the building of the boiler. The first job is drilling all the holes in the steam and mud drums.

We have 1,236 to do, and so far we have finished 824 of them – it’s boring!

The first 823 were the worst!

The first 823 were the worst!

The next job is to use a countersink bit on a air ratchet (hopefully) to de-burr the inside of all the holes.

Then we will mount the drums into the casing end-plates. and start fitting the tubes… We are using Ashby Welding in Church Crookham to plasma-cut the casing bits from 3mm plate, while the 20mm boilerplate blanks for the drum end covers and the economiser and super-heater headers are being provided by Brown McFarlane in Stoke on Trent.

Here is a picture of the CAD drawings I created to drive the plasma cutting machine…

lifu-housing-componentsv2

lifu-housing-componentsv2

Boiler Begins!

Sorry for the long silence, we have been working hard to relocate to Cumbria and convert the garage into a workshop – with that approximately complete it allows me to get started on the boiler for Befur. So this post concerns itself with this topic. Continue reading

Fuel Tank, Mast Structure and Galvanizing

This is a hotchpotch of notes on progress we have made in the last few weeks.

I am now focusing my attention on the internal fit-out. We need to get Befur in a state to move her on a trailer to our new home in Cumbria in August, this is adding some needed pressure, to ensure we get everything done in time… Continue reading