Page 13 of 17

Re: Rebuilding the Central of Georgia #408

Posted: Mon Jul 20, 2015 2:40 pm
by Kimball McGinley
Redneck; thanks for the reply on my SS and not weld joint, good to know!

Re: Rebuilding the Central of Georgia #408

Posted: Mon Jul 20, 2015 7:15 pm
by redneckalbertan
Kimball McGinley wrote:Redneck; thanks for the reply on my SS and not weld joint, good to know!
Happy I could help!

Re: Rebuilding the Central of Georgia #408

Posted: Wed Jul 22, 2015 10:43 am
by John_S
Another morning outside early, trying to beat the heat. Got the firebox door ring all welded into the inner firebox.
408_135.jpg
Firebox door ring in place
After talking with a few other builders at our RR last Saturday, we determined that the top row of stays is unnecessary. I used the material I had already cut for those stays and made plugs out of them and welded all the holes up, inside and out.
408_136.jpg
Finished inner firebox and boiler tube with finished stay locations

Re: Rebuilding the Central of Georgia #408

Posted: Thu Jul 23, 2015 1:47 pm
by John_S
Today involved clamping the firebox into the boiler and aligning it so I could transfer punch the stays.
408_137.jpg
Lots of clamps!
Once punched, the holes were drilled and tapped 1/2-20 for the stays.
408_138.jpg
Firebox with all but the front and rear stay holes drilled and tapped.
I need to put it back in the boiler and align everything again for more holes... I forgot to transfer punch the two stays in the throat sheet. The two stays in the backhead will get drilled and tapped later.

Re: Rebuilding the Central of Georgia #408

Posted: Fri Jul 24, 2015 2:02 pm
by John_S
Doesn't look like much got done, but there was a lot of cleanup to the boiler tube and the firebox today, preparing to weld it all up. I cleaned out the inside as best I could with rags and acetone so very little oil, grit, etc., is left inside before it gets all closed in. Started making up the stays and getting them started into the firebox while lining everything up and, again, clamping here and there.
408_139.jpg
Making stays and getting the firebox ready to weld in
A few more stays to finish up and then it'll be time to tack it all together and make sure everything is in the right place.

Re: Rebuilding the Central of Georgia #408

Posted: Wed Aug 05, 2015 10:59 am
by John_S
After a much needed vacation to the beach I'm back at it.

All the stays, sans the two in the backhead, are welded in. Root pass and the first cover pass on the backhead is done. Root passes and the first two cover passes are done in the mud ring. I'm done sweltering for the day!
408_141.jpg
Lots more welding

Re: Rebuilding the Central of Georgia #408

Posted: Sat Aug 08, 2015 2:28 pm
by John_S
Got a lot done the last couple days.

All the major welding is finished on the new boiler. Finished up the backhead today.
408_142.jpg
Major welding done
The old boiler has a piece of angle with expansion slots for supporting the rear end to the frame. Was easier to fab up a new one than to try to chop the original one off the old boiler.
408_143.jpg
Bracket on rear of old boiler
408_144.jpg
New bracket
Once I get the support bracket welded on I'll tackle the smokebox attachment. It's three threaded holes 60deg apart in the front of the boiler tube. The smokebox slips over the tube and is held by three bolts. Once that's done it'll be time to drop the new boiler on the chassis and see how she fits.

I'll be borrowing a reamer and tube roller next week. If all goes well putting the flues in I'll be doing the initial hydro on Saturday the 15th!

Re: Rebuilding the Central of Georgia #408

Posted: Mon Aug 10, 2015 12:53 pm
by John_S
Got the smokebox lined up and mated with the boiler tube and lifted the whole shebang up onto the chassis this morning using an engine hoist (too much for me to pick up at this point!).

Everything lines up nicely, so I mounted the rear angle bracket and TIG'd it on. Once I pull the boiler back off I'll finish welding it on along the sides and bottom. Plenty of room for the boiler to expand and contract with the slots in that angle.

The four (my error, not three) mounting holes for the smokebox are transfer punched and ready to be drilled and tapped.

It's really nice to see this thing sitting on the chassis. Even nicer that everything, thus far, has lined up perfectly!
408_145.jpg
New boiler on chassis for the first time.
Because the new boiler has washouts in the rear of the side sheets, something the original one never had, I had to hack out some of the brackets that hold the cab floor. Still need to clean these up and get them painted:
408_146.jpg
Cutouts for the rear washout plugs.

Re: Rebuilding the Central of Georgia #408

Posted: Thu Aug 13, 2015 5:39 pm
by John_S
Got the tube sheets reamed today. Then cleaned up the burrs on the inside and outside of the sheets, washed out as much oil and chips as I could inside the boiler, and she's ready for the tubes to be rolled in.
408_147.jpg
Tube sheets reamed
Tomorrow I'll put the tubes in, plug all the fittings, and make a temporary supply pipe stub and seal it with packing in the front sheet so I can do the initial hydro on Saturday morning.

Re: Rebuilding the Central of Georgia #408

Posted: Fri Aug 14, 2015 4:11 pm
by John_S
Got everything done today that I set out to do. The boiler is ready for its initial hydro first thing tomorrow morning.
408_148.jpg
Rolling tubes in the front
408_149.jpg
Rolling tubes in the back
(I had forgotten about the darn steam dome lid until late today. That would have been quite the leak during a hydro ...)
408_150.jpg
Making the steam dome lid
408_151.jpg
Ready for some pressure!
Time for a beer!

Re: Rebuilding the Central of Georgia #408

Posted: Sat Aug 15, 2015 9:36 am
by John_S
Back from the hydro. Everything went great, only a couple weepy stays to fix up once it dries out for a few days.

Hydro'd it at 300psi, normal operating pressure for this will be 125psi.
408_152.jpg
Fill 'er up!
408_153.jpg
300psi for initial hydro

Re: Rebuilding the Central of Georgia #408

Posted: Mon Aug 17, 2015 2:32 pm
by John_S
Repaired the couple of leaky stay bolts this morning, drilled and tapped the four holes for mounting the smokebox, made the hinges and latch for the firebox door (brought over from the original boiler), and got it all cleaned up and primed with high-temp paint.

Gotta try and get as much done as I can this week because on Friday I won life's lottery and must have a hernia repaired*. Don't think I'll be picking up this 142lbs boiler by myself anymore!
408_154.jpg
Firebox door installed

* hernia not caused by lifting this boiler!