Saturday 21st to Monday 23rd of April 2012, C&W Works and Castlecroft
aka Hydraulic Wars: Ernest Strikes Back!

Saturday 21st of April 2012
Attendance: 8

Today's mission was to swap the turbo bracket on the power unit for a more robust one that was fitted to Ernest's original engine. We had found that, at 1500rpm, the turbo was oscillating side to side at an alarming rate, and we were concerned that it would fail with potentially devastating consequences sooner or later.

The day began at Buckley Wells, first job was to drain down the coolant and set about prepping for removing A-end roof section and the turbo. By 11am we were ready to relocate, and using the newly arrived class 08, we headed out of C&W for Castlecroft where Andy Hardman had the Coles crane ready and waiting for us.

The roof section was soon removed allowing the team better access to make further disconnections easily and around an hour later the turbo was lifted out of the engine bay. While this was going on, Nick was busy removing the CAV starter motor from the engine and Alan was busy doing some wiring modifications to enable the newly aquired Bosch HST starter motor to work, this Bosch unit would be replacing the CAV as it was close to clutch failure. Alan also wired in the vent tank float switch to shut the engine down, as the one in the header tank and stopped working.

Once the turbo was out, Jason set about changing some hose connections on the bleed pipes for silicone based ones and the bleed on the top of the cooler group to include a small tap. Matt & Dave set about draining the oil from the turbo and removing the exhaust cover plate for cleaning out.

Meanwhile, the team removing the turbo bracket had come up against a problem, there were two studs and nuts holding the bracket to the block instead of bolts, which were preventing the bracket coming off the engine as it wouldn't come forward enough on the studs to clear them, the bottom of the bracket was hitting the oil pipe connection from the filter block. This pipe was removed, but made little difference and it was still fouling the pipe connection boss by a good 5mm. An attempt was made to remove one of the studs with the two method, and with hardly any force, the stud snapped.

At this point we decided to stop for fuel (tea & lunch) before continuing. After a break, we had another look at things and Chris managed to the bracket at a angle on the studs and knocked it forward enough to be able to get a hacksaw in. Malc set about sawing through the studs which took no time at all and the bracket was able to be removed. Another attempt was made to wind the broken studs out. One snapped again closer to the block while the other near enough wound out by hand!

Options were discussed and Nick attempted to weld a nut on to what was left of the stud, but to no joy, so it was decided that drilling it out was the only way forward. Malc offered to do this the following day so, with no other progress possible, it was decided to shunt Ernest back to Carriage & Wagon to spend the night under cover.

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Sunday 22nd of April 2012
Attendance: 5

An Early start was made and, due to the weather, it was decided to do as much as we could inside the shed. Malc set about drilling out the broken stud and Chris removed the transmission oil strainer for investigation as it appeared to be seized. After cleaning out with solvents, it was left to soak with WD40 sprayed all over it. Jason busied himself making and fitting more junction box covers.

Chris and Adam drove up to Castlecroft to collect the trubo bracket, some pipework, fittings and some breakfast. Upon return they began prepping a few items for refitting, Alan freed off the oil strainer, so Chris made a new gasket for this and refitted it. Chris then cleaned the gasket faces for the oil pipe removed the day before and refitted this along with making a gasket for the coolant pipe off the water pump. Adam set about clearing out a small coolant pipe from the water pump using some wire and compressed air.

Malc had gone for some lunch, after which he began chiselling out the remains of the stud, which was found to be a metric thread that must have been drilled out at some point in the power unit's history already, but too far into the jacket water space. The size was M16, so Malc went back to Castlecroft to get a suitable tap. A bolt was also found but it wasn't quite long enough and had an allen key head. It was decided to use it temporarily to block the water space but without washers. A suitable permenant bolt would be purchased and swapped in next week. Once Malc had returned and cleaned the thread out with the tap, the bracket was manhandled up and onto the power unit. The bolts were then entered and tightened up, the M16 having plenty of thread sealant applied!

A few coolant pipes were refitted whilst we were inside and it was also discovered that the fuel supply pipe from the fine filter to the fuel pumps would need modifying due to the different bracket. Adam & Jason quickly went off to paddy to find the pipework from the old power unit. At this point the 08 shunter was started and allowed to idle whilst air pressure built up. Around 4pm, with tools and components loaded, we headed back to Castlecroft. Chris sourced some suitable gasket material for the turbo end plate and Les busily crafted it to the required shape.

Once ready, the turbo was lifted back into the engine bay and another discovery made - the bolts we had sourced were not quite long enough, a nut would just fit on the end but it was a bit close for comfort, so these will be ordered in and exchanged next week. The team then set bout connecting everything back up - exhaust manifold bellow connections, main exhaust section, air intake bellow, coolant and fuel connections. Once done we then slung the roof section across, refitted it to the sideframes then entered and gunned up all all the securing bolts.

Ernest was then moved round to the coolant bowser for a 30 gallon 'drink' to replace fluid lost during the turbo works. Once done, we headed back to Buckley Wells where the coolant level was further topped up using coolant drained off on Saturday morning. An oil pressure test was made then the fuel turned back on and bled up to the pumps.

Alan then made a test crank with the new starter, which was successful. Around 7.15pm, D9531 burst back into life with only one coolant connection requiring nipping up! Once the engine had settled, we ran it up to 1500rpm off load to look at the turbo, which was as steady as the power unit, job done!

With smiles all round, we shut the engine down, cleaned up and headed for a well-deserved cheeky light ale (or two!) to mark the end of what was a very tough weekend, which didn't quite go to plan, but we got there in the end! A big thanks to those who helped us out over the two days.

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Monday 23rd of April 2012
Attendance: 2

Chris was present today to finish off some small jobs left from the weekend. He first set about making and fitting some new cork seals for the roof section to replace some which had got damaged over the weekend and bolted the main A end roof to the smaller roof section next to the cab. Once done and breakfast had been consumed, he then bolted up the header tank cowl and A end horn box. Next job was refitting wooden cleats to the coolant bleed pipes and roof section which we had run out of time to fit the previous day. Ernest was then utilised to move a coach onto the pit for an exam, after which the horn valve for B end drivers side was removed for investigation as it hadn't been working properly.

Ernest was then fired back up and moved outside for the underframes and wheels to be steam cleaned in readiness for painting, Chris Mills was around and kindly offered to help out with this. The loco is now complete with British Railways roundel logo and signwritten name. Chris B then had a look at the removed horn valve and managed to get it working properly. The two Chris's carried on with the steam cleaning and, once done, D9531 was shunted back into the shed, bringing the long weekend to a close.

Once again, thanks to everyone who helped out, especially with the turbo bracket swap.