adrian
Flying Squad
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MOVING COAL - A Colliery Layout in 0 Gauge
- Thread starter PhilH
- Start date
PhilH
Western Thunderer
The remainder of the layout has seen some minor progress since the original 'tour' on RMweb, although much remains to be done. Continuing over the canal bridge......
The end tippler is complete except for the wooden shelter to copy the prototype at Boothsbank, near Manchester, and possibly a small mess hut in the corner adjacent to the steps.
A temporary card mock up gives some idea of the coal washery to be provided in the corner. LarryG's pannier tank in temporary residence.
The weigh house is based on a prototype at Parsonage Colliery, Leigh, Lancashire, with unusually ornate brickwork. Unfortunately it was boarded up when I photographed it so the windows are a bit of a guess. It needed a small reduction at the rear and positioning closer to the track than the original to fit it in the available space.
The layout terminates with a single road loco shed and two lines disappearing under an overbridge in theory to other parts of the system and a connection with BR.
The end tippler is complete except for the wooden shelter to copy the prototype at Boothsbank, near Manchester, and possibly a small mess hut in the corner adjacent to the steps.
Backscenes provided by ID Backscenes, fencing by Peco and bushes by Heki
A temporary card mock up gives some idea of the coal washery to be provided in the corner. LarryG's pannier tank in temporary residence.
Both plate girder bridges were constructed from custom brass etchings.
The weigh house is based on a prototype at Parsonage Colliery, Leigh, Lancashire, with unusually ornate brickwork. Unfortunately it was boarded up when I photographed it so the windows are a bit of a guess. It needed a small reduction at the rear and positioning closer to the track than the original to fit it in the available space.
The layout terminates with a single road loco shed and two lines disappearing under an overbridge in theory to other parts of the system and a connection with BR.
PhilH
Western Thunderer
Yes, it has fooled some visitors who have remarked "I see you've extended it in to the next room". Since the next room is the loo it wouldn't be very appropriate !
PhilH
Western Thunderer
What the layout really needs is several Austerity 0-6-0STs and a project was started many years ago to scratchbuild two. Ready to run and kits of these locos have been produced in the past, although none really impressed me as being a good basis for producing an accurate model of the prototype. Maybe with the current interest in 0 Gauge some enterprising manufacturer will produce an accurate ready to run Austerity 0-6-0ST in 7mm scale.
The two prototype Austerities chosen to model were the Walkden Railway locomotives WARRIOR and WITCH, the former in red with a Giesl ejector chimney and the latter in black with the standard chimney.
WARRIOR was built new for the NCB by Hunslet and despatched via BR on 2nd September 1954, apparently arriving at Walkden on the same day, which suggests that it was delivered in steam over BR. It stayed on the Walkden Railway based at Walkden Yard loco shed until the closure of the system in 1970. Between 1959 and the late 1960s the NCB carried out various modifications to locomotives mainly intended to reduce smoke emissions following the introduction of the Clean Air Act in 1956, although increases in power and reduced coal consumption were also claimed. Details of the modifications and locomotives affected were covered by an article in the Industrial Railway Society's RECORD magazine No.196 of March 2009 by authors Steven Oakden, Dave Holroyde and myself. The Walkden Railway had a particular problem with smoke emissions because much of the output went up a steeply graded line close to Walkden town centre. The first attempt to solve the smoke problem was to burn a mixture of coal and coke, and some Austerities were fitted with extended bunkers divided into separate compartments for each fuel. WARRIOR received an extended bunker in 1959, as seen here outside Walkden Yard loco shed in 1964:
The coal/coke experiment was not a success and most extended bunkers were later removed. Various other methods of reducing smoke were introduced and the locomotives regularly used on the line through Walkden received a combination of Giesl ejector and Hunslet underfeed stoker. WARRIOR was so fitted late in 1966 and at the same time the livery was changed from black to red. It was proposed to build the model representing this stage of the prototype.
After arrival of the diesels WARRIOR was retained as spare and steamed occasionally if required. In September 1984 it was sold for preservation and moved to the Dean Forest Railway.
WITCH was likewise built new for the NCB by Hunslet and despatched via BR on 12th April 1956 "dead on own wheels" (i.e. not in steam and as part of a BR freight train), arriving at Walkden two days later. Until 1962 it seems to have worked mainly at Sandhole Colliery on the Walkden Railway, but then moved away to work at Chanters Colliery before returning to the Walkden System late in 1964 or early 1965. In 1967 it was stationed at the site of the closed Brackley Colliery to work the Cutacre Waste Tip, where I photographed it on a Saturday in the loco shed, by then the only remaining building left at the site. In 1968 it was working at Astley Green Colliery but by the end of that year it was withdrawn and stored minus plates alongside Walkden Yard loco shed. It was sold for scrap in April 1969 after a relatively short working life of less than 13 years.
The two prototype Austerities chosen to model were the Walkden Railway locomotives WARRIOR and WITCH, the former in red with a Giesl ejector chimney and the latter in black with the standard chimney.
WARRIOR was built new for the NCB by Hunslet and despatched via BR on 2nd September 1954, apparently arriving at Walkden on the same day, which suggests that it was delivered in steam over BR. It stayed on the Walkden Railway based at Walkden Yard loco shed until the closure of the system in 1970. Between 1959 and the late 1960s the NCB carried out various modifications to locomotives mainly intended to reduce smoke emissions following the introduction of the Clean Air Act in 1956, although increases in power and reduced coal consumption were also claimed. Details of the modifications and locomotives affected were covered by an article in the Industrial Railway Society's RECORD magazine No.196 of March 2009 by authors Steven Oakden, Dave Holroyde and myself. The Walkden Railway had a particular problem with smoke emissions because much of the output went up a steeply graded line close to Walkden town centre. The first attempt to solve the smoke problem was to burn a mixture of coal and coke, and some Austerities were fitted with extended bunkers divided into separate compartments for each fuel. WARRIOR received an extended bunker in 1959, as seen here outside Walkden Yard loco shed in 1964:
WARRIOR with Giesl ejector at Ashtons Field shortly after bringing up a train from Astley Green Colliery in 1970
After closure of the Walkden System WARRIOR was stored in the loco shed and steamed only 3 or 4 times a year on the limited track remaining in the works yard to shunt locomotives arriving by road transport in or out of the workshops. When I saw it in August 1976 it was in relatively poor external condition, but the following year it was repainted in a lighter shade of red and sent minus the underfeed stoker to Bickershaw Colliery where it worked regularly until replaced by diesel locomotives in 1979.
WARRIOR at Bickershaw Colliery in 1978
After arrival of the diesels WARRIOR was retained as spare and steamed occasionally if required. In September 1984 it was sold for preservation and moved to the Dean Forest Railway.
WITCH was likewise built new for the NCB by Hunslet and despatched via BR on 12th April 1956 "dead on own wheels" (i.e. not in steam and as part of a BR freight train), arriving at Walkden two days later. Until 1962 it seems to have worked mainly at Sandhole Colliery on the Walkden Railway, but then moved away to work at Chanters Colliery before returning to the Walkden System late in 1964 or early 1965. In 1967 it was stationed at the site of the closed Brackley Colliery to work the Cutacre Waste Tip, where I photographed it on a Saturday in the loco shed, by then the only remaining building left at the site. In 1968 it was working at Astley Green Colliery but by the end of that year it was withdrawn and stored minus plates alongside Walkden Yard loco shed. It was sold for scrap in April 1969 after a relatively short working life of less than 13 years.
WITCH at Astley Green Colliery in 1968
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PhilH
Western Thunderer
Starting at the front with the Giesl Ejector - the existing chimney hole in the tank (approximately 21½" diameter) was extended to the tank front as a 16" wide slot, producing a keyhole shape in plan. This was wider than required for the actual ejector chimney because it also cleared the plate fixing the new chimney to the top of the smokebox.
In order to fit the ejector in the smokebox the centre line of the new chimney was 3 11/16" forward of the existing chimney centre line, and to accommodate this the new blastpipe was formed with a slight 'S' curve. Because of this move forward, the back of the new chimney actually just cleared the rear of the original chimney hole in the tank. However the chimney hole was extended rearwards, in a semicircular shape in plan, so that the tank would clear the top edge of the ejector chimney when lifted off the locomotive. This is shown as an option on the Giesl drawing but I believe that all conversions carried out at Walkden incorporated this feature.
The gap in the front of the tank was covered by a plate held in position by the bolts fixing the top lamp iron to the smokebox front. This didn't fit flush with the tank at the top as the ejector chimney projected slightly forward.
A cast plate on the left hand side of the chimney gave the maker's details, the exact wording being: "GIESL EJEKTOR (sic), Reg. Trade Mark, SCHOELLER - BLECKMANN STEELWORKS LTD., VIENNA, AUSTRIA".
Still at the front of the locomotive, other variations included the additional footplate grab handles forward of the front steps. These were fitted to new locomotives delivered to Walkden following a fatal accident when a shunter slipped off the steps and fell under the wheels. The steps were also lined with a non-slip material.
Both WARRIOR and WITCH had the double gussets between frames and buffer beams fitted to late build Austerities and these locos also had wider brake hangers.
Original narrow brake hanger - right, Later wider brake hanger - left
At the rear of the locomotive part of the underfeed stoker system is visible below the frames. The crank at the lowest point and inclined lever are to operate a drain valve on the stoker cylinder. A plate was fitted hanging down below the rear bufferbeam (shown in red) to protect the stoker pipework from damage by the coupling chain swinging forwards.
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PhilH
Western Thunderer
The chassis will be constructed as one unit complete with footplate and buffer beams with the body in two parts - tank/boiler unit and cab. Chassis parts have been cut from brass of various thickness as shown below for the first two locos (some time ago as evidenced from the amount of tarnish)
The main frames are 0.9mm thick and have a short inner frame 1/8" thick to form the guides for the axleboxes. Top left are the bufferbeams and below the gussets between frames and buffer beams, to be fixed in the slots at each end of the frames. Bottom are the horn stays to retain the axleboxes in position. Top right are the cross members supporting the footplate to be fixed in the three slots in the top of the frames, the centre section between the frames will be removed when they are in position. Below right are various other cross members to be fixed between the frames.
The bolts and rivets will be represented by pins fixed in holes in the frames, with the heads filed to the correct size and shape, and many happy hours (?) have been spent filing pin heads. The photo above shows the holes drilled in the front bufferbeam (top) and rear bufferbeam (bottom) ready to receive the pins.
The main frames are 0.9mm thick and have a short inner frame 1/8" thick to form the guides for the axleboxes. Top left are the bufferbeams and below the gussets between frames and buffer beams, to be fixed in the slots at each end of the frames. Bottom are the horn stays to retain the axleboxes in position. Top right are the cross members supporting the footplate to be fixed in the three slots in the top of the frames, the centre section between the frames will be removed when they are in position. Below right are various other cross members to be fixed between the frames.
The bolts and rivets will be represented by pins fixed in holes in the frames, with the heads filed to the correct size and shape, and many happy hours (?) have been spent filing pin heads. The photo above shows the holes drilled in the front bufferbeam (top) and rear bufferbeam (bottom) ready to receive the pins.
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PhilH
Western Thunderer
The smokebox, boiler and tank parts have been produced by 3D printing, the 3D design being done by Alexander Clark from my original 2D drawings. The photo below shows the first trial assembly of smokebox, boiler and firebox together with a 3D printed brass Giesl ejector chimney on the temporarily assembled brass frames.
The complete smokebox, boiler and tank for the Giesl chimney version. Except for the chimney which has had some finishing work all the other items are still exactly as printed. All the required holes for handrails, lamp irons, etc have been marked with indents ready for drilling.
The complete smokebox, boiler and tank for the Giesl chimney version. Except for the chimney which has had some finishing work all the other items are still exactly as printed. All the required holes for handrails, lamp irons, etc have been marked with indents ready for drilling.
The corresponding unit for the standard chimney version.
PhilH
Western Thunderer
A friend expressed interest in building two Austerities using the Shapeways 3D printed parts, so an etched chassis has been designed for these additional locos. The artwork for the etching was kindly provided by Adrian Rowland of Northstar Design.
This design covers the earlier Austerities with single buffer beam gussets. The first etched sheet is being assembled to see how it fits together.
Some rivets/bolts were pressed through, but most were added with pins in drilled holes, located by half-etched hollows. Pin heads being shaped to represent rivets or bolts as required. A countersink 10BA screw holds the frame to the temporary spacer, after final assembly this will be removed and the hole hidden behind the sandbox whose two fixing holes are above and below the screw. The large hole ahead of the axle is for a Slaters sprung pick up.
The use of pins in holes marked on the etch allows for easy location of some detail parts.
This design covers the earlier Austerities with single buffer beam gussets. The first etched sheet is being assembled to see how it fits together.
Frames connected by temporary spacers with some detail parts added including Slaters bearings and brass hornguides.
Some rivets/bolts were pressed through, but most were added with pins in drilled holes, located by half-etched hollows. Pin heads being shaped to represent rivets or bolts as required. A countersink 10BA screw holds the frame to the temporary spacer, after final assembly this will be removed and the hole hidden behind the sandbox whose two fixing holes are above and below the screw. The large hole ahead of the axle is for a Slaters sprung pick up.
The use of pins in holes marked on the etch allows for easy location of some detail parts.
The front buffer beam shown here has a combination of rivets and bolts, the rear buffer beam has all rivets.
mickoo
Western Thunderer
I have to confess to recently becoming a little jaded with punched rivets, you can never seem to find just the right sized punch and anvil, plus bolt heads are impossible to replicate. I've a Euro project coming up that uses a lot of bolts through out the engine, heads and nuts with threaded shaft poking out, so I'd love to know where you got your pins and bolt heads from 
The resolution on the 3D prints looks good, far better than anything I got from Shapeways, I've also used GW railways and they printed well. I think it's high time this faction of modeling began to accept multimedia more, so kudos for pushing it along.
The resolution on the 3D prints looks good, far better than anything I got from Shapeways, I've also used GW railways and they printed well. I think it's high time this faction of modeling began to accept multimedia more, so kudos for pushing it along.
Yorkshire Dave
Western Thunderer
Incidentally the Giesl fitted Repulse resides on the Lakeside and Haverthwaite Railway and saw her at Haverthwaite a few weeks ago. Previously worked at Haig Colliery, Whitehaven.
PhilH
Western Thunderer
I have to confess to recently becoming a little jaded with punched rivets, you can never seem to find just the right sized punch and anvil, plus bolt heads are impossible to replicate. I've a Euro project coming up that uses a lot of bolts through out the engine, heads and nuts with threaded shaft poking out, so I'd love to know where you got your pins and bolt heads from
First you need to obtain pins with well formed symmetrical heads, if the heads aren't symmetrical with the shank they will look out of line when fixed in the holes. For the small rivets I used Amati brass model ship pins obtained from Cornwall Model Boats, these have a shank diameter of 0.5 mm but a fairly small head, so not suitable for larger rivets or bolts. For the latter I used pins I've had in stock for years and so I don't where I obtained them. They have a shank diameter of 0.55 mm and are plated brass, but the plating readily takes solder. Similar pins should be available, somewhere.
The rivets are filed to size mounted in a mini drill with a needle file, checking final diameter with calipers. For the hexagonal nuts they are similarly turned to the maximum diameter then mounted in a pin vice with a hexagonal head. Holding the head of the pin vice against the workbench, the pin head is given a couple of passes with a needle file held horizontally, then the pin vice is turned through 60 degrees and the process repeated until all six faces are done. The across flats size is checked with calipers and if necessary the process repeated. Sounds tedious, it certainly is !
I slightly countersink the rear of the holes and then bend the shank of the pin over when its been inserted, then solder in position. When the excess pin and solder are removed there should be a small amount of the bent over shank of the pin left in the countersink to stop it falling out if the solder is affected by subsequent soldering operations. But in any case you need a reasonably tight fitting hole for the pin, because otherwise the solder applied to the rear may leak out to the front face and spoil the appearance of the rivet or nut.
After installation the heads of the nuts are filed flat so they all have a uniform height.
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JimG
Western Thunderer
Many years ago the late Colin Binnie told me how he made the hex head bolts for his S scale locomotives. He also held pins in a hex barrel pin vice but used a smooth jaw vice to squeeze the flats, using the hex barrel of the pin vice to gauge the 60 degree turns required.
Jim.
mickoo
Western Thunderer
Cheers, I knew it wouldn't be easy lol. I admire your patience in filing round pins into hexagonal nut shapes, I've got rather a lot to do so I may be some while
PhilH
Western Thunderer
The etched frames still connected together with temporary spacers were fitted with wheels, motor gearbox and coupling rods to check that it ran OK.
Then it was permanently soldered together with buffer beams and various cross members.
The plunger pickups had been sited ahead of the wheel centres to keep the small part of the plunger socket protruding beyond the wheel flange behind the brake shoes. However for the rear wheels the pickups interfered with the gearbox so had to be moved behind the wheel centres and the existing holes filled in.
The next step with this chassis will be adding the footplate.