I do not want to explain why I have been absent for a while, given that so many of us are probably also feeling somewhat stressed, save only to admit that I am also suffering from Lanky (Pug!) engine withdrawal symptoms!
The next few posts will still only be in the "catch up" category, but I am promising myself some time at the workbench for this coming Christmas; no matter what the circumstance, nor consequences?!
I had been considering that completion of the chassis before moving on to more "pretty" bits was a preferable priority, but I had not fully appreciated the psychological impression of apparent project advancement rather than a sensible or practical approach?!
Fancied being naughty and making a start on sorting the boiler instead...
This is a very rough sketch of what I had in mind:
The postal tube barrel is adequately stout, but will not remain so when a section is removed from the top (later to be obscured by an opening tank and dome assembly) for locating and providing access to the battery.
Some sturdy bulkheads would suffice, and I already had sufficient quantity of 13mm MDF in stock that should be fit for purpose. Conveniently, the ideal locations for them neatly coincided with the tubeplates on the prototype! The intruding upright motor therefore fits just inside the firebox, into a slightly enlarged space between the front, and behind the brick fireback, thus making a dummy grate only marginally short when viewed from an opening firehole door! A desire for adequate battery ventilation would also be a perfect excuse for a fully detailed smokebox interior, complete with open smoke tube ends! For the added benefit of educational play value of course!
The really worrying part for me was the need to cut a series of circles and fairly narrow donut rings of absolutely spot on diameter, all with perfectly squared edges for a secure and non distorting fit inside the barrel.
Much too frightened by the prospect, I
was going to cop out and ask a friend with a computer and laser cutter for a huge favour.
Then along came Lockdown, so that knocked that jolly (cheating) idea on the head!
I would just have to do it the hard way!
Cutting slightly over size, and then spending ages carefully planing back to pencilled lines, drawn with a simple, lashed up strip-wood and nail compass was the order of the day!
That was all going laboriously, but fairly well until I managed to bust my jig saw, and ended up spending even more time dismantling the wretched machine, searching in the all the nooks, crannies and sawdust for a little errant, broken bit, and then trying to work out how to fix it with only two hands, a limited number of digits, minus one by the way, that I had previously and painfully succeeded drilling a hole in, and not having to stand on my head in an extremely cramped space!
The constant adjusting, clamping, shaving, taking down, offering up, marking out, re-clamping and shaving a bit more took it's toll! Somehow, I didn't seem to be in quite the right mood to take progress photos, so the following pics are a bit mixed up!
I should really have cut a rebate all the way round for the sake of a more accurate appearance, but that would have left too little meat for the screws and pins to bite into. The extra material should hopefully not be too obtrusive when the door is open in a gloomy and heavily weathered smokebox? Two short sections of the correct profile were needed however to locate and bolt the dart locking bar at either end.
Next came the part that I was looking forward to...
Yes, out of seven, this was the one that ended up fighting me back!
The outer edge does look rather strangely blackened and uneven in the above photo. During the trimming phase my concentration lapsed. Each time I offered it up it was way too tight all round, then all of a sudden it just fell in and rattled about. That was a dummy well and truly out of the pram and halfway down the road moment!
I had no inclination whatsoever to start over again, so desperately sought out some thin card for a shim. The only material I could find of a suitable thickness was a fairly soft, black, raggy stuff. An altogether untidy, but when well soaked in PVA glue and set, was an otherwise perfect solution.
The temporary nut and bolt in lieu of the original single, slightly below centre boiler stay was needed to help extract the plate again for the remaining extra details and finishing.
Pete.
Best get some plastic sheet underneath it or the sand will end up in the celar though.
Make sure the flux capacitor is fully charged mind 
