Tag: Test Car 2

Hello all, and thank you for joining us for another update. This week we’ve been able to finish the Shock High, made a start at clearing the Tube down and got the doors finished on B763305.

When Dave inspected the Shock High, he picked up that the underkeep bolts on the West side had no split pins in the bolts. Ernie and Charlie undid the bolts, removed the spring washers and put split pins in the holes which makes this wagon ready to release.

Nick and I went to finish off the doors on B763305. First job was the make them so they can be opened. The door chain rail has been replaced in the van’s life and it needed some adjustment to be able to lift it to clear the new doors. Part of this involved re-fixing the roof sheet between the door chain rail and it’s metal capping strip as we’ve done with more recent vans.

Ernie then finished off re-tapping a vacuum cylinder piston where the top cap had rusted and broken and sheared one of the bolts.

I measured up the back of the doors for their diagonal bracing. While not strictly necessary with us building the door from plywood, it completes the look of door externally. Dave and I cut them and then fitted them with some help from Charlie. Ernie and Nick then went down and painted the door into the traditional bauxite gloss.

Dan Baldwin went to B854782 and did some signwriting on one of the panels we’d replaced earlier in the year.

Team Baldwin and Dan deployed to the LNER Tube, needle gunning,scraping, cleaning and priming the tops of the solebars. Ernie was also on the needle gun, cleaning up the areas where plates were mounted on 1802.

Dave and I struck up the Test Car after fixing the radiator back down, attempting a air brake test after we swapped the distributor back onto the coach last week. The brakes worked more as expected, however the compressor in the coach was struggling to over come the leaking air brake cylinder. We also hadn’t swapped back the choke plate between the distributor and the spare so Dave did that while I started to remove the leaking cylinder.

With the cylinder off the coach and clamped to one of the orange trolleys, we stripped down the cylinder to see why it was blowing by. The manuals say to use some threaded bar to prevent the cap of the cylinder being fired across the work site The inside of the cylinder was liberally coated with oily/greasy schmoo. The seal has clearly been sat in it as it has swelled up, which explains the lack of movement and why I fell down when I removed it. The level of contamination is a concern for the rest of the coaches air system, so we’ll likely have to remove the other cylinder and flush out the air system, including back flushing the gauges in the coach. We’ll have to try and find a replacement seal for the brake cylinder and get that rebuilt

That probably marks the end for that pair of overalls, or at the very least that’d upset my washing machine tremendously! That wraps up our weekend, thanks for reading. Join us again next week to find out what we get up to!

Hello and welcome to a warm week’s update from Quorn; the Palshoc has its vac pipe fitted, we’ve had the Test Car open to visitors and progressed some more signwriting.

During the week Nick and Oliver worked with the C&W team at Rothley to get the vacuum brake pipe made up and fitted to Palshoc van B855568. Once completed a vacuum brake and leakage test was satisfactorily carried out.

As part of the ‘Mind the Gap’ open weekend at the GCR we had Test Car 2 open to visitors at Quorn.

We had a visit from Mark Meyts, who was instrumental in originally saving tank 3689 for preservation many years ago; he also helped promote the transfer of the wagon from Shillingstone securing its future with us last year. Thanks you Mark!

I got the Commuted Charge symbols painted on both sides of tank 3854.

With the temperatures high over the weekend Ernie and Nick resorted to light duties repairing, fettling and painting some more lamps.

On Sunday with the Test Car relatively quiet, I set up one of the Esso barrel plates in the test area of the coach ready for signwriting. The template was chalked and fitted, then traced; followed by application of the red Esso letters.

Thanks for reading, join us again next week, all the best, Dave

Hello everyone and welcome to this weekend’s update from Quorn. Both 3854 and 3689 have received more of their signwriting and details, the van train has been surveyed in preparation for a refresh and we’ve ticked off a few of the smaller jobs on our task list.

Dave got cracking with the signwriting, initially intending to get the “Esso Petroleum Company Limited” wording on the west side of 3689. The weather had other ideas with a few showers so instead Dave did the west side solebar signwriting across both 3854 and 3689.

Ernie tidied up the axle end caps on both tanks, flitting between the yellow and black paint. I started sorting out the ‘new’ paint cupboard, having to manufacture one bracket as we were one short.

Nick and Charlie arrived later, Nick walked along the van train surveying the woodwork to see where replacement sheets or planks are required. While walking down, Nick lubricated some of the padlocks. Charlie and I serviced the Petter engine on the little Leviss brake test rig, which included cleaning the fuel tank out using Danny as a slow speed tumble tank.

Dave and I exchanged the air brake distributor on Test Car 2, swapping the choke plate from the original fitment to the spare. I also swapped the auto drain valve from the bottom of the brake reservoir for one we had in stock.

Nick, Charlie and Daniel fitted the ‘two star’ registration plates for 3689 which I’d 3D printed in two colour PETG.

I focused on getting the speed rating stars on the west side of both tanks, whilst doing this Nick fitted a NOS Overhead warning flash he’d purchased from the swapmeet earlier in the day.

That wraps up this week’s antics, join us again next week where we should hopefully start working on refreshing some of the vans and finishing off the details on the tanks. Thanks for reading.

Hello and welcome to the news from Quorn; this week we have given the two tanks their identities back; with Test Car 2’s generator and Danny receiving some TLC.

Saturday started with Ross and Ernie drilling out the mounting holes in the two newly manufactured replacement spark guards for tank 3689. One guard also needed a small cut-out which Ernie applied.

The spark guards that were painted up previously were fitted by Nick and Ross, and the bolts painted.

Whilst the spark guards were being fitted Ross noticed one of the brake hanger brackets on tank 3689 had a bolt missing, so this was duly fitted. Ross also fitted new vacuum pipes on tank 3854.

I made a start on the signwriting on tank 3854, with Ross’s help to position the template in place (which was a bit challenging in the gusty wind), I then completed the Esso company lettering on the west side of the tank barrel.

Ross took a look at Test Car 2’s generator, replacing the top cover gasket on the fuel pump which was leaking quite badly. He then did some investigation of a small coolant leak which was found to be emanating from the middle of the radiator. For now we plan to try some K-Seal to minimise the leak although eventually the radiator may need to be replaced. Whilst we had the generator room doors open we were able to see that two of the six engine mounts have failed, so these will need to be replaced.

On Sunday Ross and Charlie concentrated on servicing Danny; the engine was warmed up, the oil was then drained from the engine, gearbox and differential. The fuel filter and fuel pump were also removed.

The front wheels were removed to check, clean and adjust the brakes. Whilst the brakes work the pads are low, and it’s clear that the brake system will need a complete overhaul at some point. Ross also attended to the fuel pump, fitting new bellows. Oils were re-filled and Danny was road tested (in the yard).

Nick gave the new spark guards a coat of red-oxide primer, which dried quickly allowing him to apply some black gloss. Nick then fitted the 3d printed previously painted owners plates to both 3854 and 3689, & the builders plates to 3689.

I applied the running number to the west side of tank 3854.

Then the running number of tank 3689.

Followed by the Commuted Charge logo box and star, undercoat then the first coat of yellow on both sides of both tanks. The lettering of the registration plate that remains on one side of tank 3854 was picked out.

That concludes our work this week, I’ll leave you with a couple of pics of the tanks; join us again soon as we progress nearer to releasing these two to traffic. All the best, Dave

Hello and welcome to a glorious bank holiday weekend update from Quorn. Two wagon restorations are finished and two tanks go grey.

Saturday started with Dan finishing off signwriting the two builders plates on the Lowfit B452718, whilst Mark, Oliver, Tom and Nick applied a coat of varnish to the body of the Lowfit and also the Conflat B507489.

Ernie and myself got the Esso Plate jig out and fitted the brackets for the east side of 3689 to the jig, which was then offered up to the tank barrel, checking the bracket positions before grinding each of them up as required.

With the jig in place again each bracket was tack welded; the jig was then un-bolted and each bracket fully welded in place; Charlie and myself also having a go at the welding. Once cooled Oliver applied some red-oxide to the new brackets.

Charlie did a bit of work on Edward’s frame and bodywork, however some further work is required to get him operational again to reliably provide a source of compressed air.

The Test Car’s generator was run-up to warm it through, the throttle linkage was adjusted to get the generator running speed correct to give 50Hz output; then in accordance with the workshop manual the cylinder head nuts were re-torqued up whilst the engine was warm. This involved removing the rocker cover, rocker-shaft, injectors and various fuel pipes from the top of what was quite a hot engine.

We decided to leave the re-assembly of the generator until it had cooled, so Sunday morning Ross and myself re-fitted the injectors, rocker shaft and fuel pipework, then re-checked the tappets, with only one needing very slight adjustment. The rocker cover was then re-fitted with a new gasket, new rubber top-nut seals and a smear of sealant.

The fuel system was bled and it started up first time, and the Test Car’s compressor run up to check operation, and the air used to blow-down the two tank wagons 3854 and 3689.

Having now got a reliable source of compressed air, the main focus for Sunday (on one of the hottest days of the year so far) was for Ross and myself to get ourselves wrapped up in protective overalls, masks, gloves etc and break out the paint spraying equipment. Some grey primer/undercoat was thinned, mixed and checked for consistency.

After Nick had removed a few spiders webs and bird droppings, we then set about spraying the two Esso tanks 3854 and 3689, starting with the north ends and east side of both wagons.

More paint was mixed as required and we moved round to the west side.

Nick and Ernie followed behind us with brushed to attend to parts that we couldn’t easily reach with the spray-gun.

By the end of a very warm day we had both the tanks looking very grey. The spray equipment was given a good clean out so it will be ready for when we need it to apply the black gloss top-coats.

On Monday, Nick, Charlie and Ross brake tested the Conflat and Lowfit together using the little test rig before the mercury started to climb. Both passed with minor issues, one needing a brake adjust and the other requires a bit of lubrication.

With the brake test complete, Nick got the undercoat back out and touched in more areas that myself and Ross couldn’t get to or missed.

With the weather being so hot, not a lot else could be achieved with most of the team retiring to the shade for most of the afternoon. Next week, we shall hopefully be getting the gloss out and getting the two tanks into their black top coat. Join us then and see how we get on!

Hello everyone and thanks for joining us for another update, there has been more progress on the two tanks and the Test Car has had its generator run up properly for the first time in 18 months.

Mark, Oliver and Tom finished off painting the pockets on 3689 into undercoat, once we have a good air supply again (more on that later) and the brackets are welded to the west side of the tank we can get the whole barrel into undercoat.

After taking delivery of some new (to us) machinery we’ve had a bit of a sort out in the GUV and put up some shelves and sorted some stuff off the benches onto the shelves.

After Dave and I’s Monday reassembling the generator and being thwarted by a tiny little fitting for the rocker shaft oil feed, I ordered one, but it turned out being the wrong part. Ernie can to the rescue and soldered two brass fittings of the right size together which worked quite well! I got it reassembled and filled up with fluids and with a bit of help from Charlie, got the fuel system bled up. The little Perkins lump fired straight into life, which means we can use the compressor on the Test Car while we get round to sorting out big Edward. There will be a few last small things to sort on the generator, but nothing to stop it from being used.

Dan carried on with the signwriting on the Lowfit, getting the container warning painted on the West Side. We’re very close to getting both the Lowfit and Conflat painted with a coat of varnish before releasing them both.

That wraps up this week’s efforts at Quorn. We’re really thrilled to have got the generator up and running again and looking forward to use it to progress our projects again. Join us next week for some welding and maybe even some paint (if the weather allows)!

Hello and welcome to another bumper weekend update from the team at Quorn, a day later this week as we’ve worked 3 days. Progress has been made with the Lowfit, Tank 3689 and the Test Car’s generator.

Dan has completed most of the bodyside lettering on the Lowfit B452718.

The Robins that had been nesting in the Lowfit had left the nest so Ernie, Nick and Charlie were able to loose-lay the floor; then mark and remove each plank in-turn for drilling the mounting holes. Some of the holes in the underframe also had to be opened up a little with the drill. The floor planks were then bolted in place.

Mark, Oliver and Tom cleaned out and applied undercoat to some of the end pockets and inner underframe areas of Tank 3689.

Ross, Ernie and myself marked out the positions for the Esso plate brackets on the West side of 3689, removed the paint and dressed the plate brackets that we’d previously made.

We then mounted the brackets to our special Esso Plate ‘jig’, and positioned the ‘jig’ onto the wagon. After checking the position of the brackets these were tack welded into place. The ‘jig’ was then removed and the brackets fully welded.

The brackets were left to cool, wire brushed and then given a coat of re-oxide primer.

On Monday, Ross and myself turned our attention to the Test Car’s generator. The studs that were removed last week from the old cylinder head were cleaned and fitted to the new one. The cam followers/tappets were then cleaned, oiled and fitted to the head. The rocker shaft oil feed adaptor from the old cylinder head was however not correct for the ¹/₈” BSP threaded hole in the new head, therefore one will have to be ordered.

The cylinder block was carefully cleaned and lightly scraped whilst hoovering any debris. The cylinder head mounting studs were cleaned and replaced into the block.

The camshaft was oiled then the new head gasket fitted into place. The cylinder head was then lowered carefully onto the block. The nuts were fitted and the head was torqued down in stages, strictly following the correct tightening sequence from the workshop manual.

The tappets were all set to a low position and the rocker shaft fitted into position. Rotating the crank to the correct positions as directed by the workshop manual, each tappet was then raised to the correct height in-turn and checked with feeler gauges. The crank was then rotated slowly by hand to confirm the correct operation of the valves.

The thermostat housing, thermostat, radiator hoses and inlet manifold were cleaned up and fitted using new gaskets and sealant.

The three fuel injectors which we’d previously had checked professionally were installed followed by the associated fuel pipework. The rocker cover was cleaned and loose fitted, this will be finally fitted with a new gasket once we get the new oil feed adaptor. The oil-filled air filter was also fitted.

The exhaust manifold was given a good clean out to remove as much coke as possible; the silencer flanges were then cleaned up. Exhaust assembly paste was applied and the exhaust manifold was then fitted with new gaskets along with the silencer unit which was attached to the exhaust upright flexi-pipe.

The next stage once we get the new oil feed adaptor, will be to bleed the fuel system and hopefully get the generator running again.

I’ll leave you with a sunny-side view of the Lowfit; join us again next week, all the best, Dave

Hello everyone and thanks for join us for another Quorn update. This week has been quite productive with two floors prepared, and the final prep work done on 3689.

Firstly, thanks to the funds raised last weekend at the Diesel Gala, we’ve been able to pull the trigger on getting the parts for the generator in Test Car 2. The new cylinder head arrived with some new gaskets, and a new oil filter as while we’re in there we’ll give the engine another service. Dave prepared the area around the engine and stripped the studs required out of the old head ready to put in the new one. The injector studs were a tad stubborn, but were soon released with a bit of heat.

Nick finished off the last panel of paint removal on the west side of 3689 after which the remaining bare metal area was painted in primer. While that was being done, Mark, Oliver and Tom focused on finishing the east side, leaving the end for Monday.

Dan carried on with the Lowfit, adding the lettering concerning containers on the west side.

The floor for the Conflat was also started, with Dave and Ernie cutting the rebates while Charlie and James marked them out. The cut ends were treated with preservative and eventually taken to the wagon to be drilled and fixed down. The two boards at either end needed cutting down their length to give room at the end of the wagon above the head stock such that we can easily monitor its condition in future.

The floor for the Lowfit was also marked, cut and preserved, unfortunately a little family of Robins have made their home beside the north end drawhook so while the nest is active we won’t be fitting the floor.

Tom, Oliver and Charlie stripped the remaining paint from 3689’s north barrel end and east side after which primer was applied. The tank now needs its plate lugs welding back on then it will join 3854 for a quick wash followed by the next stages of paintwork.

The little diesel test rig is in use a bit more as a compressor while Edward (our 1970’s Hydrovane) is a bit poorly, so Charlie and I gave it a once over and a clean up. This is another reason for us to get the generator and the compressor working in the Test Car again to take the pressure off repairing Edward.

Thanks for reading this week’s update, and again massive thanks to those that came to see us, purchased from our stall or donated last weekend. It has meant we can get the Test Car working again and not have to worry about trying to diagnose other faults instead of sorting out the wagons. We’ll be back again next week for another update, see you then! Cheers, Ross