The A side manifold had all the flange faces cleaned in readiness for the manifold fitting. Gaskets were made for the coolant pipe flange connections to the manifold.

 

 

 

 

 

 

 

 

Once the gaskets had been made, the top flange pipe was fitted before the manifold was lifted up and bolted into position on the cooler group.

 

 

 

 

 

 

 

 

Whilst the A-frame was in poition it was decided to make full use of this. Heavy items which will receive attention once the cooler group is completed were removed in readiness. The two compressors were lowered along with a third spare one which had been placed on the solebar. Next the compressor mounting and adjusting plate framework, which also has the drive shaft and numerous pipes and valves fitted, was disconnected in readiness for removal.

 

 

 

 

 

 

 

 

The compressor mounting framework was lifted clear of the loco, revealing a dirty greasy bedplate floor below. Removal of this framework will allow easier access to this area for cleaning and repainting once the cooler group has been completed.

 

 

 

 

 

 

 

 

The coolant pipework from A side manifold was joined up to the pipes installed from B side manifold.

 

 

 

 

 

 

 

 

Whilst the lifting was being carried out, further preparation was continuing with one of the radiator side grilles. The radiator elements recieved their next coat of paint required.

The remainder of the radiator elements required for B side, had their end castings stripped back to metal and recieved priming, and others previously treated  were painted in undercoat.

One of the radiator tunnel inspection covers that originally came with 58016 was different to the other 5, instead of having a chanel and seal around the outside, it was simply a flat piece of metal with a handle welded on. A sample was taken to a fabricators, and a replacement was made to the correct pattern. This was recieved today and is shown awaiting painting. One of the large grilles that covers the radiator elements on the side of the loco was retrieved from storage and work began stripping off the old layers of paint.

 

 

 

 

 

 

 

 

The 11 tested, painted and completed radiator elements had anti-vibration pads fitted to the sides of the elements. These pads are ribbed rubber with a metal back. The rubber ribs are glued inbetween the radiator fins on the side, with the metal facing outwards. When the radiator elements are fitted, these pads touch and keep the elements a set distance apart, preventing the fins from vibrating against each other. Once the pads were fitted and the glue set, all 11 radiator elements were fitted to B side of the cooler group.

 

 

 

 

 

 

 

 

The sloping sides of A side required a second coat of interior matt grey, so the top leading to the fans and also the inspection windows were masked off and then the whole area was sprayed. The manifold which sits in this area was also sprayed with it's final coat of interior light grey.

 

 

 

 

 

 

 

 

Another 6 radiator elements were thoroughly cleaned and prepared, whilst the 4 in undercoat recieved their top coat of light grey.

The four previously primed radiator element castings were painted in light grey undercoat. A further two elements had their old paint removed from the end castings.

With the new year welcomed in, work on the cooler group was continued – with the knowledge we can proudly say we will finish it this year! One of the compressor aftercooler pipe assemblies was sprayed in light grey undercoat, along with the manifold from A side.

 

 

 

 

 

 

 

 

Four more radiator elements had their ends stripped and cleaned before painting in green primer.

 

WOULD LIKE TO

 

WISH EVERYONE

 

ALL THE BEST FOR

 

2012!

Using threaded bar, replacement supporting brackets were constructed to support the coolant pipes. This was achieved by using a small section of pipe with a flange. By putting a bolt through one of the holes the threaded bar was held in position, whilst the bar was bent around the pipe following the contour carefully. Final re-shaping was done in the vice before being fitted in position, with a piece of rubber to protect the pipe from abrasions due to the vibrations from the loco.

 

 

 

 

 

 

 

 

The numerous nylon clamps for the compressor aftercooler pipe assemblies had any stray paint runs and dirt scratched off with a blade. The remaining 15 radiator elements for B side were pressure tested.

 

 

 

 

 

 

 

 

Studs, studs and more studs! All 104 stainless steel studs required to attach the radiator elements to the manifold, were installed on B side manifold. The studs had a threadlocking glue applied to the thread, before being screwed into the manifold. Once all were installed, new rubber gaskets were fitted on the studs ready to seal the joint between the elements and the manifold face.

 

 

 

 

 

 

 

 

One of the finished, tested and painted elements was installed on the manifold to make sure everything was aligned correctly. Once this was confirmed the side of the cooler group recieved a thorough clean – the last chance since once the elements are in place this area will be hiden. Any scrapes or chips in paintwork obtained during the last few weeks installation processes were touched up, and the bottom area under where the elements sit was re-painted. One set of compressor aftercooler pipes was hung up and sprayed in green primer.

 

 

 

 

 

 

 

 

The two curved brackets that support the curved roof to radiator grille panels were painted up in green primer. Also treated was the A side manifold, after many hard hours of preperation. We now have to wait until next year for the paint to dry before going any further!

The two small air bleed pipes from the top of B side manifold were stripped and preparred before being painted in primer. The 6 radiator elements painted yesterday, had their ends masked off before the front face being sprayed with a satin black.

 

 

 

 

 

 

 

 

The two light fittings from the radiator tunnel were dismantled for cleaning, the electrical contacts for the bulbs were polished clean.

 

 

 

 

 

 

 

 

Gaskets were made for the water pipes, first the outline shape is drawn on a sheet of gasket material. This is then cut out with a knife and then placed over the pipe flange. Using a ball pein hammer, the gasket is tapped on the corner of the holes causing the gasket to cut where tapped. Once the gasket has been tidied up using a knife, the gasket is placed on the flange and sealed with a gasket sealer paste for additional sealing.

 

The water pipework from the B side manifold was installed, along with the cross section within the radiator tunnel.

The 6 radiator elements painted in undercoat received their top coat of light grey. The tedius and labourious job of stripping the old paint from the last compressor aftercooler pipe assembly was completed.

 

 

 

 

 

 

 

 

The descaling to remove the light suface rust collected on the A side manifold over the past few weeks whilst sitting on the damp floor during the re-drilling, was continued.

With the seasons celebrations completed and the need to work off some of those extra calories accumulated over the last few days, work continued at Barrow Hill. The 6 radiator elements in primer were painted in light grey undercoat whilst the radiator tunnel flooring panels were unwrapped from storage and installed in position.

 

 

 

 

 

 

 

 

Stripping of the last compressor aftercooler pipe assembly began, alongside the final descaling of the A side manifold in readiness for painting. Prior to the descaling work the manifold recieved a flush through with high pressure water jet to remove any swarf and other contaminants.