June 12th-14th 2011, Baron St Works, Bury

Sunday June 12th 2011
Attendance: 6

The day began with Jim & co being tasked with refitting the brackets and compressor aftercooler which has been painted the previous week. Jason busied himself cutting metal gussets for the auxiliary air tank frame to be welded in.

Chris was joined by work colleague Bruce Walker to assist with the soldering of the main pipework runs from compressor to air tanks. Bruce and Chris brainstormed the pipework runs then, whilst Chris went on the hunt for fittings to screw into the air tanks, Bruce had a practice run with one of the fittings to ensure he was ok with everything and the equipment worked correctly.

Once Jim had finished fitting the air aftercooler, he welded the support gussets Jason had been cutting for the auxiliary air tank frame. This was then allowed to cool before refitting after lunch, Chris and Bruce wandered up to Castlecroft to pick up a check valve and also have a spot of lunch.

Jim refitting the Aftercooler pipework	... and welding strengtheners to the aux tank frame

After lunch Jim & Co refitted the aux air tank frame and condenser unit. Bruce and Chris started on the compressor to after cooler pipe run. Chris had found a pipe with the correct fittings on that was only slightly short so Bruce made and extension piece up and with an elbow recovered off another air tank, the original flexible was now able to connect up, saving the cost of having a custom one made in the future. The after cooler to condenser run was next, but it soon dawned that we were shy of a suitable fitting although all of the pipework was cut in readiness.

Meantime Jason & co were cutting out a mangled area on A end roof section for repair. The skin was cut away and the bent angle had the side cut away. Kris & David busied themselves with slacking off the roof section so that it can be barred around to allow a gap for the cork gasket to be inserted at each end once cut.

Bruce soldering the front pipework run	Roof section cut out revealing bent angle

Chris fitted the check valve into the outlet of the condenser, then bruce started cutting pipework for the run from the check valve into each air tank. The gas gun we had was not getting enough heat into one of the connections so a mini oxygun kit with appropriate nozzles was brought into action as it would connect to the gas bottles in the works and this would be the way forward. But with time pressing on, the end to a very long moist heavy rainy day was called.

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Monday June 13th 2011
Attendance: 3

Bruce & Chris were up early and into the works, the aim was to finish cutting all the required pipework for the cab end of the tanks then solder all the joints. Chris made a list of the missing fittings required which included 2 Elbows, 1 Threaded union, a reducer and a female threaded fitting for the safety valve to screw in to. Chris then spoke to Ian Riley who kindly ordered what we needed on our behalf in the hope they would arrive the next day.

With the pipework runs all cut, Bruce then set about silver soldering each joint on the rear pipe work run. This was done off the loco on a bench and required the two T pieces setting in position, marking then soldering to the marks on the bench.

Pipework and flexible from Compressor to aftercooler	Aftercooler to large condenser, showing missing fitting

Meanwhile, Jim had arrived and had been busy making and fitting brackets for the compressor to aftercooler pipework and protecting the aftercooler from vibration fatigue. After lunch, Bruce & Chris were busy with Jaguar motor repairs so they could get home the next day! Jim continued with making brackets to support the aftercooler pipework.

Around 7pm, Bruce and Chris returned to D9531 and carried on soldering, this time the front pipework run from check valve to the air tanks. Again this was done on the bench and all the elbows and T pieces needing marking then soldering in position on the bench. Once done at around 9pm, Chris & Bruce called it a day.

Run from check valve showing T into first tank pre-soldering	Bruce soldering the front pipwork run	Rear run from both air tanks, T for saftey valve and run to small condenser

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Tuesday June 14th 2011
Attendance: 2

Bruce and Chris were up early and pressed on. The front pipework run was refitted and tightened up. The rear was removed again to solder some damage in a pipe, then the pipe was refitted. It was then a case of then hanging around for the missing fittings that were ordered the previous day to turn up.

At midday there was still no sign, so Bruce & Chris decided to pack up and head home. The pair will return for a day to finish off the pipe work with the necessary components. This will then complete the air system from the compressor, through the aftercooler, large condenser and check valve, into each main air tank and from each tank down to the small condenser. This will then take air supply up to the brake frame with the pipe size dropping in size from 1¼" down to 1", ½" and ¼".

Front pipework run contructed	Front pipework run fitted up from check valve to both air tanks

Thanks once again to everyone who came along this weekend and particulary to Bruce for his help with the air pipework.