Welcome to the homepage of the BDP. The latest updates, news, etc will appear here and then will migrate to the relevant part of the site to be replaced by the next new item.
Returning visitors will know all about us and our aims, new visitors may like to browse the site starting with the 'About us' link to the left.
A limited number of worksplates replicas cast in aluminium are available for sale. They are the same design as the ones to be carried by our recreated loco. These will be highly polished and painted, when finished they will be indistinguishable from those mounted on the loco. They are available at £85 each and can be ordered here - see the sales page for details.
These pictures show the opposite ends of the 'before and after' scale in this update. The first is the mess under the conduits which pass through the engine room floor to feed the traction motors. These are located under what was the radiator compartment so there was a perfect combination of oil, grease and water accumulated over years and years. On the plus side the lubricants acted as a barrier to the bi-metallic corrosion seen in previous updates but on the minus side someone had to remove it. This is pretty much what all the floors in the whole loco were covered with at one point.
The second two photos show a hole in the no. 1 nose floor going back to the time when the nose was removed from the loco. It was a rough cut at the time and it's finally been filled with some nice new (and straight) plate, seen in the third photo waiting to be fully-welded in during the next shift. The two trip-hazard tabs are simply to prevent the plate falling through the hole and will be removed later.
The fourth photo is shows the lifting eye (which was temporarily welded in to allow the nose to be removed and repositioned) finally being removed as part of the floor renewal. The person undertaking the work appears to be perfectly happy being bent double all day and says he's looking forward to doing the same at no. 2 end once this end's finished.....
Just one photo for this update but one which demonstrates the enormous amount of time necessarily spent on the design side of the project, rather than the build time.
The object shown is a clamp which, along with its five friends, holds the engine room roof in place.
The five component parts of the assembly are drawn on Solidworks CAD, laser cut (including cutting the weld preparations) in 10mm thick S275J/JR mild steel and sub-fabricated in a jig off the loco. They are then welded into position using 1mm ER70 wire with a Argon/CO2 shield.
The weld process was approved by an independent engineer as were the stress calculations for the parts as individual pieces and as an assembly.
Following the attachment to the body a sample was tested for flaws using a Dye Penetrant (DP) process. In accordance with our Quality Management System, 10% of the total welded on the day should be tested - although in reality this amounts to one of the assemblies (you can't test 0.6% of an assembly....).
Once the dye, developer and weld residue has been cleaned off the entire area will be painted in BR Spec. 81 primer, undercoat then topcoat.
Finally, once the roof is finished and all the other relevant parts of the loco are mounted on it the roof will be secured properly by torque tightening the fasteners, locking the nut with a Nord-Lock washer and paint marking to show any movement.
Time taken for design, fabrication and preparation = 2 days.
Time taken for welding into position and taking a pretty picture = 10 minutes.
Nice and simple update this week, the cab cupboard which used to penetrate the radiator room has been removed, it got in the way and we won't need in-cab storage in the converted loco. Also, the engine room floor cleaning continues with the plates being thoroughly de-greased then roughed up with a flap wheel before painting in the normal manner. All done without me too - well done team.....