May 28th & 29th 2011, Baron St Works, Bury

Saturday May 28th 2011
Attendance: 4

The main aim for this weekend was to get B end ready for receiving pipework and also complete a few outstanding A end jobs. Jim and Adam teamed up to remove the exhaust brackets that were welded in the previous working weekend; although they worked perfectly in securing the pipework, they were mounted in a way which meant the aftercooler could not be removed. A redesign was agreed upon using removable angle iron and U bolts. Jason set about making strengthening gussets for the air tank frame on the fire bottle side and a bracket for the small condenser out of U section.

Adam grinding brackets off	Redesigned aftercooler fixings	New small condenser bracket

Chris set about changing the fine fuel filter on the power unit, as fuel starving had been reported following the previous weekend's work. Luckily we had another of the correct type in stock so this was fitted the engine run up to ensure all was well. Chris then set about refitting the air intake bellows, now complete with internal strengtheners, installed by Jim, that will prevent them collapsing under full load conditions. Jason then joined Chris and the pair went to hunt out the fire bottles for B end. These were luckily located in a nearby container and each was transported back to the loco on a trolley.

Chris refitting air intake bellows	Air intake bellows refitted	Fire bottle in transit!

Having finished the aftercooler brackets, Jim and Adam moved on to welding in the frame gussets and small condenser bracket that Jason had made earlier. Then, with all hands on deck, space was made and cleared ready for the fire bottles. With a heave and a ho, each was lifted into B end and located. Last job of the day was to remove the aftercooler pipework which was then taken to the support coach for a sand down and coat of primer.

Jim welding air frame gussets	Both fire bottles in position	Adam priming the aftercooler

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Sunday May 29th 2011
Attendance: 5

Some of the team were required to attend meetings, but while they were away Kris busied himself making cork strips for the air tank frame and gluing them into position. Once everyone was back, Chris got the works 08 and shunted D9531 outside. A steam cleaner was then set up and both nose ends given a good blast to remove accumulated dust and dirt.

Kris and David extracted the main reservoir air tanks from storage where they had been painted and brought them round to the loco side. These were then lifted into the frames with the Manitou. D9531 was then run up to allow it to dry out after all the steam cleaning and, once dry, shunted back into the works. Jason then removed the aux air tank frame mounting that sits on top of the brake frame. This was then taken round to the coach where a start was made on modifying it so it only has one tank saddle instead of two.

Chris steam cleaning B end	Both main air reservoir tanks back in place

Auxiliary air tank frame alterations	Jason glossing aftercooler pipe

Jason finished off the day by applying a coat of white gloss to the air aftercooler pipework that Adam had sanded and painted in primer the day before. All equipment was packed away and the weekend's work called to a close.

As has happened several times during the D9531 project, we've been thrown an overly generous handful of glitches and problems to overcome - we shaln't be beaten though!