Section 13 - Boiler

The boiler was fabricated by Godshall's Machine shop in 2003 and was part of the castings and prints when I purchased them. Started Jan 2010
BoilerInspection13Jan10 003
13-Jan-2010. Kind of an odd perspective here, you are looking inside the smokebox. The boiler is vertical standing on the floor and the smokebox is sitting on…
FirepanFabrication21April10 002
While Bill was putting the holes in the pan, I chucked a piece of 5/8" steel tube in the lathe and turned out eight air intake tubes. In the background you can…
FirepanFabrication21April10 001
21-April-10 We switched back from working on the Freight Elevator to the firepan because I acquired some wet refractory grout to line the pan with -- only the…
BoilerPrep20Jan10 003
20-Jan-2010. Filing the factory bevel on the end of the boiler. The bevel is put on the pipe at the time of manufacture so the welders (when joining it to…
BoilerPrep20Jan10 002
A look at the bevel edge that has to go. Another reason we need a flat surface is the boiler is not actually round, unlike the smokebox. The 12" pipe was cut…
BoilerPrep20Jan10 001
Bill takes a large file to see how much of the factory welding bevel we will have to take off to make the smokebox fit on the end. Conclusion: A lot. Time to…
BoilerRearSupportBracketWelding24Feb10 001
24-Feb-10 We decided to weld the boiler mounting bracket to the bottom of the boiler instead of bolting it like the print calls for. I didn't want to grind all…
SmokeBoxBoilerMountingRing3Feb10 004
3-Feb-10 The smokebox to boiler mounting band has been rolled, sized and welded together. We have had to adapt the blueprint plans to the boiler since the…
SmokeBoxBoilerMountingRing3Feb10 003
Bill test fits the band. We are getting close to the right diameter, looks like we need to cut a little more off the ends. This is not the final position of the…
SmokeBoxBoilerMountingRing3Feb10 002
3-Feb-10 My poor aged pinch roller suffers abuse when I roll the 3/16" thick, 1-1/2" wide mild steel. The wooden stand the roll is on wobbled, swayed and jumped…
BoilerRings10Feb10
10-Feb-10 The rear boiler mounting bracket has been fabricated, temporarily installed and the angle bracket clamped in place to be tack welded.
BoilerRearSupportBracketMounting17Feb10 002
17-Feb-10 After considerable effort to remove the smokebox from the boiler thanks to the now Press Fit boiler band (instead of a slip fit), we prepare to finish…
BoilerRearSupportBracketMounting17Feb10 001
Match drilling the rear boiler support bracket. We had to remove the wood blocking holding the boiler up to install the support bracket. Using machinists jacks…
BoilerRearSupportBracket13Feb10 004
Using a 1/2" 4-flute cutter, we side mill the required angle into the bracket.
BoilerRearSupportBracket13Feb10 003
Here's one of the blueprint mysteries: How do you bend a 3/4" angle 3/16" thick to a 7 degree angle?? I don't know how you hold this small bracket to bend it…
BoilerRearSupportBracket13Feb10 002
13-Feb-2010 Machining the rear boiler support bracket plate. After waiting 5 weeks from my metal supplier, I finally have some stock to work from. First we laid…
BoilerMounting6Feb10
6-Feb-10 The boiler temporarily installed on the chassis, front smokebox mounting ring welded to the boiler.
BoilerMounting6Feb10 006
Strips of metal used to fill the gaps between the out-of-round boiler and very round smokebox and mounting ring. You can tell I'm not an experienced…
BoilerMounting6Feb10 004
6-Feb-10 The first mounting of the boiler on the frame. The orange strap is keeping the boiler tight against the smokebox until I can weld the mounting ring.…
BoilerMounting6Feb10 003
Previously, the mud ring on the bottom of the boiler was ground a little bit flatter to better fit the firepan, and the front of the boiler was ground to fit…
My buddy Al stopped by and gave Bill and I a hand. Here we are mounting the smokebox to the cylinder saddle in preparation for the boiler.
Saturday 6-Feb-10. Another wet, snowy day outside means no track work, we retreat to the shop instead! Bill and I drill and tap for eight 10-32 screws to hold…
24-Mar-10 Once again I have to thank the generosity of others to have the right tool when needed. Here we are trimming the fire pan width to fit the actual…
Here's one of those 'get around to it' tasks. While we had the boiler upright, we needed to cut the dry pipe down a little. As delivered there was only 1/16"…
24-Mar-10 One week later with a new tap wrench and new skip tooth pipe tap, the holes are threaded quickly and easily. So easy in fact we had to check to see if…
10-Mar-10 The boiler with four rings finished, next to the backhead band. The smokebox mounting ring doubles as the jacketing mount band.
10-Mar-10 We rolled the boiler band mounts, slipped them over the boiler and used bailing wire ('Ford wire' said Bill) to squeeze it down for tack welding. We…
16-Mar-10 You can see both cleanout bosses here. I did not have a "Straight" handle style tap wrench large enough for this reluctant tap, so we tried to use a…
16-Mar-10 After welding two more cleanout bosses on the back of the boiler, Bill tries to tap the 1/4" NPT hole. Even with an oversized hole, a new cobalt…
3-Mar-10 Tacking spacers for the boiler band mounting rings on the shell.
Laying out the guide bar position.
The air intake tubes are spot welded to the fire pan and the burner brackets are ready to be positioned and welded. We used a sizing block to make sure they…
We decide to mill the damper guide bars from solid instead of a buildup as shown on the print.
Bill works on the burner mounting brackets while I weld on the fire pan.
26-April-10 I decide I will weld 1/4" thick bars to the bottom of the boiler to anchor the firepan. I will drill and tap them to match the pan mounting holes…
With the pan bolted to table to keep it in one place, we drill two holes for the burners in the end, and finish the holes with the knockout plug cutters.
Tempering a new riveting buck after hardening it. This is O-2 oil-hardening steel. We used 40 psi for the riveting gun for the rest of the rivets.
Too much pressure! This is the broken end of my riveting buck which shattered while putting the damper guide bars on. Bill thought 120psi was a 'little too…
5-May-10 Match drilling the fire pan damper guide bars to the pan. We machined them from solid instead of the build up like the plans call for because this is…
While Bill was making a new Riveting buck, I took some mild steel mending wire and did my best to spot weld it to the pan for the refractory cement would have…
7-May-10 Since the bottom of the boiler is very uneven, and I don't want to drill and tap blind holes into the mud ring, I tack welded 1/4" thick flat stock to…
I'm pretty happy with how it turned out seeing how this was my first time ever working with this cement. And it only took me an hour for this job. Yes, the…
10-May-10 Oh Happy Day, I finally have the refractory cement in the fire pan! I have been hanging onto this wet, fiber reinforced cement for almost a month now…
11-May-10 Here is the fire pan baking on the grill. I thought the fiber reinforced refractory cement would air dry, but this morning I found it uncured and…
The boiler under construction by Wayne Godshall
The firebox with a view of the crownsheet stay bars.
The firebox before installation.
View of the finished boiler sitting in my garage leaning against the wall. It is very heavy and took three people to unload it. It is 50" tall or about the same…
Bottom view of the big firebox. Inside the firebox you can see the copper ends of the flue pipes, called flues, these will allow the coal smoke to pass through…
End view or smokebox view of the new boiler. The perspective is a bit strange since the 50" boiler is sitting on the floor leaning against the wall and I had to…