We are a group of volunteers who volunteer with the Kent and East Sussex Railways locomotive maintenance and overhaul dept. We work in a fun and relaxed environment but whilst carrying out essential work on the KESR locos. We have been working for 4yrs and comprise around 10 - 15 members. If what you see interests you then why not consider volunteering with us? We welcome people of all ages, skills and backgrounds. No previous experience is necessary!
We're into the summer season and the K&ESR is in full swing. Since the start of August we have been running our "red" service that sees two steam locomotives in operation. This puts extra pressure on the work that the loco dept does as availability levels have to be higher. Given we're not exactly flushed with operational locos either we need to do our job well!
25 Northiam overhaul
The Saturday Gang continues to work on 25 Northiam's overhaul. Progress has been slow and steady with further reassembly taking place. A key area of continued focus has been the wheelsets. As shown in the previous blog post we had stripped them down to the bare metal: during June this was completed and the wheels were progressively painted. A few coats of protective red oxide were applied, followed by grey primer. Once we got some slightly hotter weather in July we proceeded to paint them in a suitable black gloss paint. A seemingly small task like this can take up alot of resource!
Saturday Gang giving 25's wheels a gloss black top coat
25's wheels painted - with tape to stop
people from touching the paint!
However we haven't just been working on the wheels. Work continues to reassemble the frames and install newly repaired components back from where the came. The pistons & con rods have been connected up to the crosshead. The reverser mechanism has also been connected up to the crosshead. The "innerds" of 25 are slowly but surely being put back together.
Pistons now added (in the middle of the slide bars)
Crosshead fitted, reverser mechanism
(equivalent of gears in a car) connected
Attention is also being given to the axleboxes, we cannot lower the frames back onto the wheels without these. Checks have been made to determine the wear and any adjustments required.
Checking 25's axleboxes for wear
Works at the "front end" have been completed which has meant we have been able to reinstall the front bufferbeam. A small step perhaps but it does seem to, aesthetically at least, make 25 look a little more like a loco than just a large kit of parts.
Front bufferbeam refitted to 25 Northiam
Slowly but surely we are getting there! There's a fantastic spirit in the Gang at the moment as we continue to battle against the odds to return 25 to service. This is by far the hardest challenge we have had, much more extensive and complicated than Charwelton or Norwegian's tender overhaul. As always though we're rising to the challenge through a mixture of camaraderie, cake / biscuits, tea and appalling jokes! Special thanks is due to our steadfast regulars who keep the project going.
376 Norwegian
Just a brief update from the previous blog post, 376 Norwegian has been fully lined out and is in service. A point to note is that due to extensive frame strengthening works, Norwegian's power rating has been increased from a "3" to a "4". The number denotes how many MK1 carriages a loco can haul over the K&ESR. The highest we have is "5". This increased power rating has seen Norwegian haul the Pullman set, loads heavier than previous periods in service.
376 Norwegian after a day on the "B" set
DS238 Wainwright
With 376 Norwegian's overhaul now firmly in the past, efforts have been stepping up to return DS238 to service. Works are centring around the firebox and frames. As you can see from the below photos: repairs are taking place to the outer firebox and the frames are being progressively cleaned and painted.
DS238 Wainwright under overhaul, note frames painted
In the works / news:
Inspecting 23's spring hangers
The Saturday Gang has been busy assisting in the running maintenance of the K&ESR. For example, after 28 days in steam a locomotive requires a boiler washout, a mechanical exam and usually some kind of repairs! We have been assisting the main loco dept in carrying out such maintenance / repairs. A example of this is the work that we have been doing on 23 Holman F Stephens (currently on washout having completed 28days in service). A mechanical exam has been carried out, the tubes swept out and removal of a broken spectacle plate. The aim is to ensure the locomotive continues to perform efficiently and ensuring that any potential issues are spotted before they cause damage. Often unseen but this work is essential. No maintenance - no trains!
A collage of scenes showing Sat Gang volunteers at
the controls of 23 HFS, under the supervision
of the K&ESR operating assistant
The Saturday Gang was privileged enough to be rewarded with our own equivalent to a "Railway Experience Day". As you know, we are not locomotive crew, we don't physically operate the locos. However on occasion we are given the chance to sample the fruits of our labour first hand. Supervised by qualified operating staff several of our members had the opportunity to drive 23 Holman F Stephens up and down a short section of line (Rolvenden station to Sewage Works siding). This serves as a wonderful reminder of why we do what we do. Without our works, the locos simply wouldn't run. Needless to say we all thoroughly enjoyed driving 23.
We are delighted to report that 65 Maunsell has returned from her holiday at the Embsay & Bolton Abbey Rly and will be back at the head of the MK1 or Pullman set in due course.
65 Maunsell - back from the E&BA Rly
6619 has had some remedial repairs carried out. Work has also been undertaken to prepare our resident Pannier (1638) for a boiler ticket extension. All being well the inspector will grant a further year of running.
Unfortunately Marcia suffered some issues some months ago, recent investigation found an issue with the firebox. This will necessitate the loco being stripped, the boiler lifted, and extensive repairs being carried out. A shame seeing as Marcia was only back a few months.
Marcia withdrawn with firebox problems
Can you help?
Some of the Saturday Gang, pictured a few years ago
The Saturday Gang is made up almost entirely of volunteers. The loco dept provides skilled craftsmen to supervise and guide us in our work (hence why our regular cratfsmen are part of the gang!). However we are in real need of extra people. The workload is large and some more help would go along way. If you look at what we do and think "that looks interesting but I can't possibly do that" then don't worry! All of us started without experience and built up our skills through training and working with others. We train and teach people all the skills they need which come in very useful in all walks of life. If you're at all interested or would like to know more than leave a comment on the blog or email saturdaygang@gmail.com. If you're still not convinced we'd be happy to show you round the works and demonstrate what we do. So what are you waiting for people?!
Welcome to this belated Saturday Gang Report for April and May.
First of all apologies for the delay in getting this published. Our editor has been busy of late and hasn't had time to assemble all the material. However better late than never!
Even though the blog has been quiet over the last few months the Saturday Gang has been anything but! We've really got stuck into 25 Northiam over the past few months as there has been a bit less running maintenance to carry out than usual. We're pleased to say that there has been lots of progress!
Busy in Rolvenden workshop with 25's frames and wheels on the right handside
Work continues apace on the motion reassembly. Last time round we showed you the slide bars installed, well after much work we are pleased to show you the pistons installed. The pistons are a very important part of the motion so we've reached another milestone in the overhaul. Installing the pistons into the cylinder bores requires careful alignment, otherwise potentially fatal damage could occur. The glands are currently being installed and finalising / testing the connections to the rest of the motion should occur during June. Once complete we will then fit the con rods and connect the pistons up to the crossheads, still plenty to do!
Pistons installation progressing. Final lining will be undertaken in June
Measurements being taken to set the slide valves correctly
Beginning to set the slide valve port faces
With us looking to re-wheel 25 Northiam in the near future we turned our attention to the wheels. Like much of the loco they had years of grime, grease and previous coats of paint all mashed in. Using our steam cleaner we blasted off the surface rust (had been stored outside for a number of years) and loosened up many of the layers beneath. We then used a variety of hand tools (such as a needle gun) to strip the wheels and reveal the bear metal beneath. Although it doesn't sound much it took several days of constant effort to bring them to this state. During June the work will be completed by giving the wheels a thorough sanding, then we will crack test the wheels to ensure they're fit for service. The non destructive testing equipment we have at Rolvenden is excellent at picking up even the tiniest of cracks. If all that goes well we will paint the wheels in primer and hopefully rewheel the loco in a few months (depending on progress of the frames).
The initial steam cleaning of 25's wheels
Needlegunning the wheels down to bare metal
Going forward we are looking to refit the buffer beams and refurbish 25's axleboxes. Slowly but surely reassembly is gathering pace. The key thing of course is to do the job well and get it right.
Pistons installed into cylinder block (refit the bufferbeam soon we hope!)
In other news:
376 Norwegian has re-entered traffic for another 10yr period (2013 - 2023). There was a slight mishap with some gauging issues at Tenterden but these have now been resolved. It's good to have her back! No doubt you will see more of 376 Norwegian during our main running season in July - August. It's really pleasing that something we worked on (the Saturday Gang overhauled and recommissioned the tender) is operational again. It really reminds us of why we volunteer and why we're not doing the other 100 things on a Saturday. Anyway, here's a few photos. The first shows the tender that we received to overhaul, the second shows it finished and coupled to the loco, the third shows the loco ready to go!
376 Norwegian's tender prior to Saturday Gang overhaul (note plants growing in it!)
376 Norwegian's finished tender, ready to roll!
The completed locomotive & tender
Elsewhere in the workshop: Efforts on DS238 Wainwright's overhaul will step up now that 376 Norwegian is finished. The intention is to return this loco to service for a 5 year period to use the exisiting components to the end of their lifespan. Once the loco completes 5yrs it will be withdrawn for a full overhaul which will include fitting a new firebox.
DS238 Wainwright's overhaul progressing
So overall (no pun intended!) we have been very busy and made excellent progress. There are plenty of challenges just round the corner but we're looking forward to them. The work wouldn't be fun if it was easy!
We're now fully into the running season so there's plenty of work to come. So we're appealing for more volunteers. We really need more volunteers to continue our work and ensure the K&ESR has operational locomotives now and in the future. Its great fun and you don't need to know anything to volunteer. So why not give it a go? If you'd like to visit, even just to see what we do then please get in touch at saturdaygang@gmail.com
Our photo album (to be updated soon): www.kesrloco.co.uk If you haven't already please like us on facebook: Saturday Gang Facebook Page Thank you for reading, please feel free to comment or send any questions you may have. Saturday Gang
At the end of March we started our running season and as such its been busy getting everything prepared and ready. We were hoping to be able to start "de-winterising" the locos but the bitterly cold temperatures have meant that we're still using frost precautions. These frost precautions prevent damage to the many precious components on a steam locomotive.
The Saturday Gang has continued to make steps forward with 25 Northiam's overhaul. Happily during March we began the reassembly process. All of the preparatory work has come together and the first few parts of the motion have been refitted. The slide valves are now in position: reassembly is a time consuming and heavy process and has to be very accurate otherwise the loco simply won't go!
The motion reassembly literally "getting of the ground".
This is the valve gear beign lifted up onto the frames for installation
Re machined slide bars now in place
Looking in towards 25's cylinder block,
note the newly installed slide bars
The painting of the frames is finally complete, it felt a bit like the forth road bridge project at times but we got there! Only a small part round the cylinder block remains in undercoat because further works are to take place. We have also removed a considerable amount of rust from inside the footplating which was causing a bulge on both sides of the cylinders. Work like this can only take place whilst the loco is dismantled.
Much like the Forth road bridge painting project!
Further machining has been taking place and more components are being prepared for reassembly. Putting a steam locomotive back together is much like completing a jigsaw puzzle, all the various parts fit together but they will only go together properly in a certain way.
Machining works on 25's pistons continuing
Note one of 25's new pistons being skilfully machined
Elsewhere in the workshop, the overhaul of 376 Norwegian is progressing with a few of having a steam test in early - mid April. It will be very good to have Norwegian back after a 7 year absence from traffic. Not forgetting of course that the Saturday Gang overhauled Norwegian's tender (quite a novelty given she is the only tender engine we have!) and has assisted on the loco with various tasks.
376 Norwegian - due to be tested soon!
Once again the Saturday Gang has been running various training sessions on a variety of machines and equipment. Another lathe training session was run where the basics of lathe operation were explained, along with all of the calculations which is the hard bit!
Looks complicated - and it is!
All of these training sessions are good because not only do they help to train a future generation but they also help members when applying for jobs. Another of our number found employment on the big railway the other week, with his work at the Saturday Gang making him stand out from the crowd. So if you would like to learn new skills in a fun environment why not give volunteering a try? If interested please contact us at saturdaygang@gmail.com
Many people often wonder what the status of the Kent & East Sussex Railway's locomotive fleet is. What is in service, what's in storage, what's under overhaul etc.
Here's an update with a photo of each of our locos in current condition.
Under overhaul / out of service
376 Norwegian - In the final stages of a 10yr overhaul. Should be back in summer 2013
25 Northiam - Overhaul well underway, boiler complete and frame reassembly is beginning.
DS238 Wainwright - Overhaul is underway with works on the boiler in progress
753 P Class - Currently dismantled, awaiting overhaul to start.
24 Rolvenden, currently in store in Sewage Works sidings. We hope the overhaul of 24 will begin once 376 Norwegian is complete though this is to be confirmed.
In service
3 Bodiam - In service. Boiler ticket expires 2016
32678 Knowle - In service. Boiler ticket expires 2019
23 Holman F Stephens - In service. Boiler ticket expires 2013
1638 - In service. Boiler ticket expires 2013
6619 - In service, currently receiving minor repairs. Boiler ticket expires 2013, though my get 1yr extension
14 Charwelton - In service. Commonly used on the K&ESR Railway experience days. Boiler ticket expires 2019
65 Maunsell - operational but currently on loan to the Embasy & Bolton Abbey Railway. Boiler ticket expires 2018
+and+the+completed+batch+of+boiler+tubes+13.11.10.JPG)
+02.05.09.jpg)