Saturday Gang Report January-April 2015

Hello everyone. Apologies for the radio silence over recent months, but a lot has happened since the start of the year. First of all, we must goodbye to our previous blogger, and Saturday Gang founder, David Hunter. Having spent 9 years working on the Kent and East Sussex Railway, David has moved on to focus on his professional life, and we all wish him well in his travels.

The start of the year is always a varied time for the Saturday Gang. The reduced winter service and pressure of exam season makes it an occasionally quiet time, yet it is almost immediately followed by a spike in progress as Easter approaches. With that in mind, let's take a look at what's been happening with some of our regular locomotives.

Locomotives:

Hunslet Austerity 0-6-0T 25 'Northiam'- Our unofficial main overhaul continues. Since the start of the year, the loco's chimney has received some attention, including new holes drilled to secure it; the chimney has since been returned to storage. We also returned our attention to the tanks, drilling out the bolt holes inside. After removing the foundation ring at the end of 2014, we have since received it back from the works, along with new side plates ready to install. This job is expected to be completed imminently, and it is our hope that 25 is closer to the end of its overhaul than the beginning.

GWR 5600 Class 0-6-2T 6619-  Our newest loco has just finished its ticket, and so the first part of the year has been dedicated to stripping it down. We've seen to it that the firebox is clean, the boiler has been washed out, and the blast pipe and all valves in the cab have been removed. The loco is currently residing on a siding, visible to passengers bound for Tenterden.

Manning Wardle O Class 0-6-0T 14 'Charwelton'- This loco suffered the misfortune of a frozen water tank this winter, quite a rare occurrence on an operational loco! It is currently undergoing maintenance, and we have had to clear the faulty sanders, remove the fusible plugs, and conduct some general inspection. As of the end of April, it remains in the shed.

LB&SCR A1X Class (Terrier) 0-6-0T 32670 'Bodiam'- There are few problems to report with this loco, apart from a buildup of rust on the underside. The addressing of this problem can be seen in the March Report.

WD USA Class 0-6-0T 65 'Maunsell'- The railway's current workhorse remains in service. But the Saturday Gang have made some small contributions to it, such as the addition of a new warning sign to the cab, regarding the loading gauge. Also, one of our volunteers gave its smokebox door a new coat of apexior in April.

GWR 1600 Class 0-6-0PT 1638- The resident pannier tank remains out of service. Some work has been done on the smokebox ring recently.

Videos:

https://www.youtube.com/watch?v=8xp1JhBh5Y4
https://www.youtube.com/watch?v=A0ypFk_3i20
https://www.youtube.com/watch?v=OnT3SeXYVe4
https://www.youtube.com/watch?v=w_7VLBy3SO8

That's all for this Saturday Gang Blog entry. We anticipate the next entry towards the end of August. In the meantime, be sure to like us on Facebook and subscribe to our YouTube channel, SaturdayGangVideos. Until next time!

https://www.facebook.com/pages/The-Kent-and-East-Sussex-Railways-Saturday-Gang/346493445395124?fref=ts

https://www.youtube.com/user/SaturdayGangVideos

Saturday Gang 2014 Review

Another year has passed us by so in order to continue this blog's short traditions, let's look back on 2014.

25 Northiam's overhaul 

Unsurprisingly we will start by looking at the progress made throughout 2014 on n.o 25 Northiam. 

25 Northiam - frames finished off

It was in March / April 2014 that we completed rewheeling 25 and achieved the status of 'rolling frame'. We refitted the conrods, big ends and various ancillaries such as the sanding pipes. This essentially completed our work on the frames so we moved back to the boiler. 

The boiler required some remedial works which were made apparent by our NDT (non destructive testing) techniques. We also proceeded with further works to prepare the boiler to be reunited back with the frames. Extensive repair and modification work was carried out to the ashpan and it's linkeage connecting it to the motion. We proceeded to 'clean' up the boiler after a considerable period of time outside in the elements. This involved considerable manual labour with the needle gun, followed by painting sessions. During later 2014 our efforts turned to the firebox works, after a comprehensive set up various rivets have been replaced. The Saturday Gang is currently working on the foundation ring and preparing for that to be fitted. 

Saturday Gang working on 25's boiler

As you can read there (and throughout the year) the Saturday Gang has made good solid progress on 25's overhaul. It will be satisfying when it's over as this will be our toughest and longest challenge to date. 

Maintenance / Running repairs 

Recent work on 23 HFS

Throughout the year the Saturday Gang has been involved in routine maintenance and running repairs. This work is essential in ensuring the locos which have boiler tickets are available for service when required. This work brings variety to our task list and is quite different in nature to overhaul work. This variety of tasks keeps things interesting and ensures we're not doing the same things over and over again every week. 

During 2014 we have carried out maintenance on virtually all of the K&ESR's locos and this essential work will continue in 2015. 

24 Rolvenden 

24 Rolvenden - on her way to the CVR

Readers of our blog will know that this is not new news, however sadly during 2014 we had to say goodbye to 24 Rolvenden. This was poignant for us as the Saturday Gang had the privilege of 'having a go' at driving 24 on her last day of service. We also stripped 24 and prepared her for storage, at that time, pending overhaul. However circumstances changed and it was decided to sell 24 to a suitable bidder. The positive side of this is that the Colne Valley Railway are taking good care of her. Nontheless, 24 Rolvenden will be missed. 

People 

Some of the Saturday Gang!

As is tradition we close with a section about 'us'. The Saturday Gang is it's people, all of us make us what we are. Railway preservation tends to be very focused on the locos rather than the people behind them. Of course being part of the dept responsible for overhaul / maintenance we don't expect the spotlight to be on us. We get satisfaction from being the unnoticed guys and girls who make our customers happy, and make running steam trains possible. 

As always the Saturday Gang is an incredibly happy and joyful place to be. We have had a couple of new starters in late 2014 who are most welcome. One member remarked how much fun it is to be involved and that we make something that is normally associated with 'boring old farts' fun. We gathered for a few social events outside our normal workshop duties throughout the year, showing we're as much a group of friends as 'colleagues'. 

Saturday Gang day out during August

We'd like to take the arrival of a new year to launch a new appeal for volunteers. Our work is entirely dependent on us (or potentially you!). Therefore we invite anybody with an interest in engineering, railways or just needing something to occupy them on a Saturday to come and join us. Absolutely no experience is required, even one saturday afternoon every few months would be such a help. Not only would you be helping to preserve the K&ESR locos but you'd be gaining new friends and practical skills. Don't be afraid to get in touch. If you're not sure but would like to know more please get in touch at saturdaygang@gmail.com

Wishing you a happy and prosperous 2015, 

Saturday Gang.  

November & December 2014 Report

Welcome to November & December's report.

Introduction

Persuading 23 to dismantle!

November is a quiet month for the K&ESR, trains don't run (with the exception of the special on the 11th). December is entirely different, the Santa Specials are an integral part of the K&ESR's business each year. These trains require two 4-5 coach sets and two locos capable of pulling them. Thus November was busy in the loco dept, getting locos prepared for the busy December period. When much of the K&ESR goes into hibernation the loco dept and Saturday Gang keep busy!

It's certainly becoming a challenge supplying enough motive power for K&ESR needs: With only 6619, 65 & 376 capable of hauling the Santa Special trains it certainly is important to ensure the locos are well prepared. This issue becomes even tougher in 2015 as 6619 is due out for overhaul. Still, it would be boring if it wasn't a challenge - wouldn't it?

Overhauls

25 Northiam

Work on the boiler has continued apace, attention has shifted to fitting the foundation ring to the firebox. The chimney has also been returned to the shed to be fitted. Although it doesn't sound like much the work on the foundation ring has taken up many of our Saturdays in December. Please see December's video report (linked below) for more information. 

Note inner and outerfirebox stays. 

Preparing the foundation ring for fitting. 

DS238 Wainwright

DS238 Wainwright is slowly coming back together, the motion reassembly is continuing (as you can see in the photo). The pistons and valve gear are being repaired and put back together. Boiler repairs are ongoing, the patching being done on the firebox is getting close to completion. Reassembly of DS238 may be completed in 2015 though that depends on further progress and satisfying various inspectors.

1638

1638 stripped, note centre driving wheels removed

1638 has been stripped down further since the last report. The frames afre currently residing in the shed, safe from the elements. The centre set of driving wheels have been removed for further dismantling.

In the works / news from Rolvenden

65 Maunsell: In service.

65 Maunsell on the New Year's Pullman
- photo courtesy Elliott Waters

32670 Bodiam: Winterised.

32678: Winterised.

753 P Class: No progress to report.

12 Marcia: No progress to report.

14 Charwelton: Winterised.

376 Norwegian: In service.

23 Holman F Stephens:

Two volunteers removing 23's ejectors

The Saturday Gang worked through most of November on stripping n.o 23 for storage. Removing key components such as the ejectors, gauges etc protect them from elemental damage. Dismantling a loco is in many ways easier than rebuilding it but nontheless some components haven't been disturbed since the previous overhaul, this can make it difficult to remove them. Indeed some components were well 'cemented' into position, still as ever we enjoy a challenge.

Removing the firebars, no fire in 23 for a little while.

We had great fun dismantling 23 as on occasion it involved a little DIY (destroy it yourself) using a hammer! Some components such as the brick arch can be recycled but cannot be reused, so we assure you it's not needless destruction! Of course where components can be reused we remove them with care and ensure they're stored correctly.

Doing this sort of preventative work is so important because it minimises the costs / effort required to return the loco to service. Roughly speaking, it will probably be at least 12-24 months before 23 is put through an overhaul. Thus the work we do now is ensuring the loco is stored in the best possible condition. One of the Saturday Gang members wrote an article in the Summer 2011 edition of the Tenterden Terrier detailing the process for storing a locomotive. So for further details please purchase a copy!

Returning re-usable firebars to the stores.

6619: Available for service until end of December.

Videos

November 2014 (for some reason blogger can't find this so below is the hyperlink):

https://www.youtube.com/watch?v=vake1Gh3sOY

December 2014:

The Saturday Gang hope you had a merry Christmas and wish you a happy new year.

Saturday Gang

September & October 2014 Report

Welcome to September and October's Report

Introduction

Volunteers working on 25's boiler, note the access staging

Well the main summer running season passed and we're rapidly heading for winter (both weatherwise and traffic wise). The K&ESR slows down after August and runs fewer trains. This takes the pressure off a little though these 'quieter' months are our oppurtunity to catch up on work and ensure the fleet is ready for the Santa Specials.

Locos are coming out of traffic in quick succession, n.os 23 & 1638 have both been withdrawn from service upon expiry of their boiler tickets. This has reduced the pool of 'Class 5' locos quite substantially (the K&ESR rates locos according to how many MK1 carriages they can pull). With 6619 due out at the end of the year this will present challenges in 2015. However we're always up for a challenge!

So without further hesitation, deviation or repetition let's see what's been happening.

Overhauls:  

25 Northiam: 

Volunteer setting up a spring bush for machining

The Saturday Gang has continued to make progress with n.o 25 over the past few months. The frames were moved for the first time since their reassembly, this was part of a general re-org of the shed to allow 25's boiler to be brought back inside. The frames are currently sheeted and well protected from the elements, unfortunately under cover space is rather limited at Rolvenden so they may end up back outside at some point, hence the 'cover up'! The video report for September shows machining bushes for 25's springs and preparing the frames for movement (see below).

Removing rivet heads, with a powered chisel

As mentioned previously, 25's boiler has been brought back in. Remedial works had been identified some time before but only now are we in a position to address this. Time had to be spent setting up the lobo staging to give us a platform to work from. Work to replace failed rivets is underway, it's quite a laborious process.

DS238 Wainwright 

DS238 brought 'back down to earth'

Progress continues to be made on DS238's overhaul: the frames have been lowered back onto the wheels and motion reassembly is progressing. The firebox is coming along too, the cut out section of the outer firebox has been welded up and further works on the outer firebox are underway. Still a long way off returning to service but certainly encouraging signs. 

1638 Pannier 

1638's boiler, lifted from the frames by the steam crane

As mentioned in the introduction, 1638's boiler ticket has expired. The loco dept has wasted no time in lifting the boiler out of the frames and dismantling the motion. A full assessment of the works required to return 1638 to service will be done, then begins the process of repairs and reassembly. Although 1638 is in ok mechanical condition it will be few years until she steams again, though once DS238 is completed more attention can be given to 1638. 

In the works / news from Rolvenden

32670 Bodiam: Available for service.

32678 Knowle: Available for service. 

753 P Class: No progress to report.

P Class awaiting attention

12 Marcia: Stored in Orpins sidings awaiting remedial works to begin.

14 Charwelton: Available for service.

376 Norwegian: Available for service.

23 Holman F Stephens: Suffered a failure in service which lead to an early withdrawal for overhaul (only a week!). The current plan is to store n.o 23 until other overhauls are completed. During November the Saturday Gang will be stripping n.o 23 and preparing for her for storage. All the components such as ejectors, gauges, piping etc will be placed into secure storage. 

6619: Repairs / washout completed. Available for service.

6619 shortly before works completed

65 Maunsell: Available for service. 

Videos 

Two video reports are available, covering both September & October. 

September 2014: 

October 2014:

Many thanks for reading, 

Saturday Gang 

July & August 2014 Report

Welcome to July & August's report

Introduction

Saturday Gang enjoying a 1st class trip on the K&ESR
(on our day off, not a Saturday!)

First of an apology for the lack of updates, both on the blog and youtube. We try our best to keep things updated but sometimes we get a bit behind or other things are going on. 

The summer has been busy as always, the K&ESR has been running it's 'red' timetable during August. This requires two steam locos in service everyday and sometimes another for Pullman duties. This would in part explain why much of our attention has been on maintenance duties, more so than usual. However once the main running season is over we hope to return our focus to n.o 25 Northiam's overhaul.

We also used the Bank Holiday Monday to sample the rest of the K&ESR. It might seem strange but we don't get to see much of the railway we volunteer for other than our own 'bit' at Rolvenden. So we had a very enjoyable day out on 'our' railway. It was satisfying to see two locos we had worked on previously (23 HFS & 376 Norwegian) in service. It reminded us of why we do what we. It was also good to meet for some well earned fun! We are not just 'colleagues', rather friends in the Saturday Gang and one of the main reasons we volunteer is the social aspect. 

So let's go through what's been happening: 

25 Northiam

Needlegunning 25's boiler

As mentioned previously our attentions have been focused on maintenance works but that is not to say we didn't make any progress. 

25's ashpan has been finished off, the linkeage has been fitted and painted. The coupling rods have also been burnished . We continued to needle gun the boiler (as reported last month), this was completed and then we completed painting the smokebox in appexia paint. We have also greased the frames in preparation for them to be moved outside, quite literally we now have a 'rolling frame'. Once works on the boiler are complete the frames and boiler can be re-united though this is a little way off yet. We also took the opportunity to examine the spare austerity springs we have. The ones already on the frames have been checked but a ready supply of spares is always helpful.

Frames prepared to move

As is so often the case with loco overhauls, each week is a small step and one day it all suddenly comes together. During the winter season we will be making a concerted push on n.o 25. However as with all good things they come to those that wait. 

DS238 Wainwright

Building up the firebox on DS238

Work on the boiler is ongoing. The firebox has been 'built up' to increase the thickness of the plate, especially round the foundation ring. 

In the works / news from Rolvenden 

32670 Bodiam: In service

32678 Knowle: In service 

753 P Class: No progress to report

P Class awaiting further attention (we will get there eventually!)

12 Marcia: Stored in Orpins sidings awaiting remedial works to begin.

14 Charwelton: Repairs have been completed and the loco has been tested. The new bearings had not bedded in before the loco needed to be moved. This made some interesting noises during the shunt! See August's report for a listen.

Remedial works complete on n.o 14

376 Norwegian: In service

23 Holman F Stephens: 

1638: In service

6619: Under maintenance. The Saturday Gang has carried out much on this loco. We started with rodding the tubes and prep for washout work. Then we did some work on the tubeplate, this was so encrusted with dirt that a needle gun was required to clean the tubeplate. A thorough test of the lubrication system has also been undertaken. As 6619 approaches the end of her ticket it is even more important to undertaken this work. 

Saturday Gang working to repair 6619's tubeplate / blaspipe

65 Maunsell: In service

Videos: 

Two video reports to cover this period: 

July 2014:

August 2014: 

Many thanks for reading, 

Saturday Gang 

June 2014 Report

Welcome to June 2014's report.

Introduction 

Team photo! - Not everybody was here though

It's been a busy month down at Rolvenden for the Saturday Gang (yes we say that every month!). Progress on n.o 25 has been continuous and  we have done a good share of running repairs / maintenance too. 

We have also had some new starters which is very encouraging, they are most welcome. Perhaps unusually we have had two new female starters, just goes to show the girls can get stuck in just as much as the lads! We had quite a large group in one Saturday (though it doesn't show all of our members) so we took an opportunity to take a group photo. We hope that is shows us as we are, happy and proud of the work we do. 

Sadly 24 Rolvenden has left us (see feature below) but there is much to be positive about. The Saturday Gang continues onward, striving to return n.o 25 Northiam to service and keeping the other locos in service. New members always give us encouragement and it is people that are important above machines. 

25 Northiam 

Progress on 25 Northiam's frames

Last month we showed the ashpan being constructed. During June the remaining sections were welded up and we commenced painting. The linkeage for the door mechanism on the ashpan has also been completed. The con rods have been burnished making them gleam in the light. 

We have begun work on n.o 25's boiler again. There are various items of work to be carried out before the boiler can be tested or reunited with the frames. Naturally a period outside in the elements will have its effects. So our first job has been to needle gun off surface rust and do some more painting. The smokebox requires a thick and rather gooey apexia paint which is heat proof. We have been attending to the smokebox, the door is needlegunned and painted but the sides and front ring will be completed in July. The foundation ring has also been cleaned in preparation for the non destructive testing. The washout plugs have also been removed, cleaned and reinstalled. This process is known as 'boxing up'. 

Painting the smokebox door

Currently the boiler is waiting on NDT testing and an ultrasound scan to check for cracks. 

Goodbye old friend - 24 Rolvenden 

24 Rolvenden on day of depature (Bradley Bottomley)

As some of our readers may be aware - n.o 24 Rolvenden has been sold to the Colne Valley Railway. N.o 24 was moved down to Wittersham Rd loading point and departed the railway on Friday 20th of June. A team from the Colne Valley also came back to pick up some spares we had for sale. 

N.o 24 Rolvenden has been part of the furniture of the K&ESR since 1971 and has been almost continuously in service (in between overhauls). A particular memory of the author's is a few Christmases ago. We only had n.o 24 and n.o 23 in service, nothing else was operational - one failure could have caused disaster for the K&ESR Santa Specials. Fortunately both n.o 24 and n.o 23 were magnificent and ran continuously between the first weekend in December till Christmas eve. A tribute to the robustness of the Hunslet Austerity. 

The Colne Valley have a feature on their website: http://www.colnevalleyrailway.blogspot.co.uk/2014/06/a-new-arrival.html 

In tribute, here's a few pictures on n.o 24 through the years. 

24 Rolvenden at Northiam in 1994

Undertaking works in the motion

The Saturday Gang assisted in reboring 24's cylinders in 2009

Photo of Saturday Gang with 24 upon completion of works

24 Rolvenden on Santa Special duty, Christmas 2009

In the works / news from Rolvenden 

32670 Bodiam: In service after a successful steam test.  

32670 under steam test

32678 Knowle: In service

12 Marcia: No progress since last report 

14 Charwelton: Repairs are ongoing, works have begun on the firebox. 

14 Charwelton repairs ongoing

376 Norwegian: As of end of June / early July loco under maintenance. 

23 Holman F Stephens: 23 was under washout and routine maintenance but as of beginning of July is available for traffic.  

Saturday Gang working to refit the spark arrestor

1638: In service 

6619: Failed in traffic with a broken spring so was under repair for most of June. 

65 Maunsell: In service. 

Videos

June 2014 video report: 

Many thanks for reading, 

Saturday Gang 

March, April & May 2014 Report

Welcome to the report, covering March, April & May 2014.

Introduction

Volunteer drilling bolt holes in a new section of plate for 25's ashpan

Although the blog has been quiet and hasn't been updated since February this doesn't mean the Saturday Gang haven't made any progress, quite the opposite! The editor has had his exams / end of year exams recently so hasn't had time to sit down and update. Hopefully this latest blog post will put that right. 

The K&ESR has begun to run trains again and because the DMU has been out of action for essential repairs, a second steam loco has been required. Normally on our quieter times of year we only use one steam loco with the MK1 set. Though it increases the amount of running maintenance it is good to see our smaller locos getting a run out. 

The Saturday Gang has been kept occupied with various items of running maintenance and of course progressing n.o 25 Northiam ever closer to completion: 

25 Northiam

Saturday Gang discussing further works on 25's ashpan

The overhaul has taken some quite big steps forward since the last report. The big ends were retrieved from the storage container (and made quite a lengthy journey on a trolley into the workshop, see the video report). The conrods have been refitted and the motion is now fully reassembled. We barred the loco backward and forward to check that everything moves freely. We have also begun to fit some of the other non motion components such as the sand pipes. This is a large milestone in the overhaul as we can now start the final preparations to reunite the boiler and frames.

A major task that has been occupying us for the past couple of months is the repair of the ashpan. This box sits underneath the firebox and collects the ask from the fire. As you can imagine the heat and ashes corrode and distort it over time. Much wasted platework has had to be replaced, a new lid and bracket have been manufactured. Perhaps this doesn't sound much but it has taken much careful and time consuming effort. The ashpan will ultimately be fitted beneath the boiler. It's another piece in a very large jigsaw puzzle. The series of photos below shows the various different works / skills that have been used in this project. 

Measuring and squaring off platework

Marking out holes to be drilled

Grinding off weld excess

Cutting slots for the door mechanism to fit

Smoothing out the slots with an angle grinder

Works on 25's ashpan so far!

DS238 Wainwright

DS238 - note the lobo staging in front of the loco

The overhaul continues, repairs on the boiler are ongoing. To facilitate the works required on the cylinders and motion some lobo staging has been erected. This creates a safe platform from which to work. 

753 P Class

753 P Class - note needle gunned front frames

A little progress has been made, some needle gunning has been carried out on the frames (as you can see from the photo). Some more of the P's many components have been cleaned and stored. As has been written before though, this project is a low priority and most of the loco dept's attention is focused elsewhere. 

In the works / news at Rolvenden

32670 Bodiam: In service

32670 Bodiam in the yard

32678 Knowle: In service

32678 Knowle - receiving repairs prior to a return to traffic

12 Marcia: The boiler has now been lifted out of the frames so remedial work can take place on the firebox.

12 Marcia's boiler - now removed from the frames

14 Charwelton: Charwelton has been receiving a number of repairs over the past few months, we have assisted in the program of repairs. Tasks such as renewing firebars, rebuilding the brick arch and refitting the firehole door guard have been undertaken.

14 Charwelton under repair

376 Norwegian: In service 

376 Norwegian - running up to Tenterden for the evening Pullman

23 Holman F Stephens: The Saturday Gang has carried out a number of repairs to n.o 23 over the past month. The sand boxes were heavily corroded so were removed, repaired and refitted. N.o 23 has also had a bit of a bend in the running plate for a while (where it came from we're not quite sure!) so whilst she was out of traffic we took the opportunity to straighten the plate. A new injector valve had been procured and the Saturday Gang assisted in installing the joints and fitting the new injector in place.

Volunteer curing the bend in the running plate!

24 Rolvenden: Readers may or may not be aware that for some time n.o 24 Rolvenden has been up for sale. The latest news is that the loco is close to being sold, the deal may be confirmed shortly. Though currently we know little more than you do! 

24 Rolvenden - in slightly happier settings than it's current location

1638: In service

1638 in the yard

6619: In service

6619 ready for traffic

65 Maunsell: The loco is currently being prepared for another spell on loan away from the K&ESR. Location is to be confirmed.

65 Maunsell & 23 Holman F Stephens in the yard

Videos / Photos 

March 2014 Report:

April 2014 Report: 

If you haven't already please 'like' us on facebook: Saturday Gang Facebook page

Many thanks for reading, 

Saturday Gang