Steam Locomotive Cylinder Head Repair
HTML-код
- Опубликовано: 15 сен 2024
- The 1917 Vulcan Iron Works steam locomotive at the Georgia Museum of Agriculture developed a steam leak on the front left cylinder. In this video, we take the head off to determine the location of the steam leak and then do a fix to the head - repairing a tapped hole for they cylinder drain cock in the museums machine shop by using the Wells Index vertical milling machine to mill a pocket out above the old hole and replacing it with a cast iron plug that was turned to size on a Lodge and Shipley metal lathe and then tapped properly. This was then brazed and locked in place with some set screws. With this repair, we can get our narrow gauge train back on track!
Support VintageMachinery.org on Patreon:
/ vintagemachinery
Please Visit: www.vintagemach...
Sponsored by:
American Rotary Phase Converters
www.americanro...
Use checkout code "Vintage10" for a 10% discount on all AD, ADX and AI converters!
I believe you said toward the beginning that the valve could be operate from the cab. I should have like to have seen how that was accomplished. A very ingenious and straight forward repair that should hold for another 100 years!
A few hours before I watched this video, I watched one showing #5 in action. I remarked that it seemed to be running in 3/4 time. Puff---puffpuff---puff---puffpuff. The video showed the shadow of the steam exhaust on the ground nearby and the gap was clearly visible. THIS video explained the reason why! The leak at the drain valve was robbing the steam pressure from the chimney (and the drive rod) on the left rearward stroke. I'll bet she ran as smooth as glass after this repair. Good job! Thanks, guys.
I can see where your brass cast valve goes now. Making things right on 100 year old machines that have been compromised by get-by fixes is the same here as it is for trolleys at our shop. “It needs to run just a little longer and then we’ll retire it or sell it or park it.” I’m glad you take the time to do it right.
The beauty of steam propulsion. It never dies. it just keeps going back to the workshop and comes out as good as ever. Never mind the twentieth century, many nineteenth century locomotives are still giving good service in preservation societies and not just rusting on plinths. Keep up the excellent work Keith. Incidentally I worked for a firm that built steam locomotives. I never saw them using any thing but a lathe and drill press to shape a cylinder head.
So true. And that part could have been made on nothing more than a lathe and drill press!
EXCELLENT WORK!!!...MOST PEOPLE HAVE NO IDEA HOW MUCH PATIENCE IS REQUIRED TO BE A MACHINIST, OR A MECHANIC FOR THAT MATTER. PROBABLY TAKES A FAIR AMOUNT OF EFFORT TO PRODUCE THESE VIDEOS AS WELL. THANKS FOR TAKING THE TIME!
Hi Keith, You're right! This repair was something that I enjoyed watching. And I have a thought about the drain cock. As a live steam model railroader, it is common for switch locomotives without leading trucks to derail and break off the drain cocks. You have said that the Vulcan was used by a series of different places. I would hazard a guess that many of them had tight curves and yard switches that received poor or no maintenance. Therefor it is quite likely that on of the previous owners shops moved the drain cock to eliminate more repairs after the Vulcan went on the ground once again. What ever happened in the past, I think the change to the drain cock was a quite creative solution. Thanks for the video, Larry.
That very well could be true. Most of the places this locomotive was used was on construction jobs with temporary tracks. I am sure that life was rough in those days....
Hey, a machinist doesn't get to determine what goes wrong, especially when he volunteers to do the work at a museum. I enjoyed watching the repair. I was raised repairing things that otherwise may have been replaced altogether. Thanks Keith for including us in this repair. Greg
My pleasure Greg!
Its such a beautiful sight to see vintage steam machinery running again. And to know there is people who care enough about it to keep it running. Brings tears to my eyes
I have a place in my heart for steam engines and it is quite a privilege to be able to help keep this one running!
My grandfather, a pipefitter/boilermaker, enjoyed sharing his times at the Union Pacific Shops. He always warned about the dangers of steam leaks. "If it cuts steel, it would certainly cut you". Especially high pressure steam not being visible until several feet from the leak. I believe by age 17, I could refit a locomotive from his stories.
Cool stuff! Keep up the good work.
Those are treasured memories. A lot of expertise will die when these old tradesmen pass on. What I would give to have one of those old railroad refit shop guys with us when we are doing this kind of work. Oh the tricks we could learn!
Fascinating to see how something built before WW1 was built. Not as many departures from modern manufacturing as I had expected. I greatly appreciate the time-lapse segments which shorten the viewing time without the feeling of missing anything.
Thank you!
Videos like this make RUclips fun for me, thank you👍🏻🇺🇸
Dang Mr Rucker, that's very respectable! To be involved in maintaining such a historic machine says a lot about your skills and abilities!
I love watching milling, and metal lathe machines, it's amazing how they cut the hard steel like it's butter. Great Video.
Great video, I learned a lot. I work on heavy trucks and can appreciate the work you do. Thanks for keeping our heritage alive.
I was fortunately able to swamp for my grandad packing tools,lots of grease and oils and memories and now on occasion get a call from the museum for minor repairs such as these.I am 60 now and know of no one to take my place.Thanks gramps.Memories forever.
Great memories. They are priceless!
I was an understudy of a radial engine mechanic from WW2, who ran an automotive machine shop. Opened my shop in 1971. His penetrating oil of choice was "Maltby" for disassembling. Would suggest you try it. I never fould anything better, particularly on broken exhaust stud removal.
Glad I spent 35 minutes of my life watching this, never know when your neighbor might need help working on his 1917 Vulcan Locomotive 😂😂😂
Now you only have one problem - the other side !
I was surprised that the head came off that easy , i was expecting at least a couple of broken studs !
Excellent video and a nice repair !
For now, the other side is not leaking, so if it ain't broke, don't fix it.
Great Job. Thank You for sharing your wonderful life with us.
Great workmanship and it's great to see someone working on an old steam engine!
Keith this project reminds me of my Dad. As a young man in the 1950's he was Fireman on steam locomotives for a few years. Thanks for the video.
Very cool - I wish I could have done something like that when I was a young man!
Hi Keith, i like you're Engagement in all you work it is visiable👍 but if it where my loko, i'll fix that with a threatbushing , maybe outside M22 x 1,25 and the 3/4" Inside! 100yearsOld cast Iron normaly don't like pointet hot torches, if you not heaten the whole Part,to avoid Cracks. My Grandfather whas "once uppon a Time" a engineer on Prussia T16 ,i ' am once volunteer in a mecanic Shop in a musea: www.flickr.com/photos/22328570@N02/albums/72157621744312510
Thanks to all volunteer's all over die world , and never forget: "Keep the Fire burning, don't prays to the Ashes!"
Having welded and chased bronze art statues for 20 years, I so wanted to clean up that braze slop with a die grinder.
IronheadOfScroteus e I’m w
IronheadOfScroteus
I sympathize with you! I‘m a dentist and we are all a bit obsessive compulsive by training and trade. And on top of that I have a photographic memory. So that blob is going to stay with me . Even if it‘s covered up I know now it‘s there!
cast on cast was a great choice . Thumbs up Keith !
Thanks!
My Late High School shop teacher must have been rolling in his grave watching this machining job! No cutting oil at all! All Dry! Wonder what Mr. Pete222 would have said about that. LOL. Nice repair job, solid and well thought out. Good job Keith.
In my college courses, I was taught not to use cutting oil on tungsten carbide cutting tools. If you are using high speed steel cutting bits then oil is required. coolant fluid seems to be different though and somewhat universal (it's smart to look it up if you are cutting an unfamiliar material).
Nice repair. I work in a chemical plant and am around steam pretty much on a daily basis. It's amazing the damage it can do, especially at 600 PSI!
Our locomotive runs at 150 PSI max! 600 PSI is scary!!!
Well Done. Not your first rodeo on Maintainance and Machining, EXCELLENT WORK!
I always like to watch you restore and maintain the antique machinery in the museum. Keep on keeping on.
Thank you!
Thanks for the video, Keith.
Usually, when you find something you need to fix, it seems that by the time you're finished, it's not just repaired, it's bulletproof.
I try to do that, but bullets don't always bounce off of things like I hope....
Superb as usual.. Thanks Keith Lloyd - DigiTek Say hi to your helpers from all of us viewers
Thank you and will do!
I'm glad to see the care you give the old girl... it appears she's served you well, and will continue once she's had her day at the spa!
She has been a workhorse for many years now and deserves the attention that she gets!
Thank you, Keith, for a beautiful video of a very respectful repair. It probably hasn't seen that much precision in it's lifetime.
Dear Keith that's a very handy tool i don't know how many times i needed something like that
Not sure which tool you are talking about, but I suspect it is the stud puller. Lots of people are commenting on that one. You can get them at most auto parts stores.
I ment the tool you used on the studs
i just like watching ppl repaire these steam trains spechily w/ such care it means there still some ppl who love them in this world
craftsmanship at its best ... tapping by hand on a blind hole ... make perfect sense !
Always a pleasure to watch true craftsmen at work!
I love how big and hearty everything is...lends itself to repair quite easily. Nice Job!
As long as you can handle it....
I loved the video and ejoyed seeing one of these old engines ripped appart. I just jumped to your channel and need to check out your other videos.
Thank you for putting this up for all to view
Bryan
Another great video. Thanks Keith and thanks for explaining the process clearly. Regards MachineNZ
My first reaction was shock when you milled off the heads of the setscrews, but then I realized there's essentially zero possibility that they will ever have to be removed. I guess it was just my inherent bias against any unrepairable assembly.
I am not sure that you could remove it if you wanted to - even without the setscrews!
I would have installed 2 studs, and used bolts for the rest of the holes. That way they would be easier to remove down the road instead of having to remove all of the studs to get the head off.
Great job on repairing the head, and drain valve. Awesome video.
Thanks!
I thought the location of that pipe on a sloped area with half its threads exposed looked like an engineering fail, and I guess it really was. Your repair looks SOOO much more secure and professional. I have always been impressed with guys who can put their hands on something and see what needs to be done without a single CAD drawing or engineering consultant to help them. Very impressive.
Thanks - I guess you just learn how to do this stuff over time.
I enjoyed watching this from start to finish. Your solution to basically add additional meat to the low-side of the thread with an insert was a good choice. This was a great video to watch and I really appreciate the extra time you spent for editing this. Keep up the great work.
I like to see the diversity of KR's skills and the interesting work he does. I also learn something new in just about every video. More importantly I like to see his methodical approach to work and especially the quality and integrity of the workmanship. If Keith does flower arranging I'll watch that too! By the way the Japanese Police are taught flowering arranging as a means to develop skills, attention to detail and appreciation of art.
Perhaps I should do some flower arranging then. That is a skill that I totally lack....
Me too! I think my significant other will hit me with the vase knowing how I would stick the flowers, hopefully right end up!
Nice job Keith. When torquing a component, a manufacturer sometimes instructs us to start off with a lower torque, then work up through 2 or 3 intermediary settings. That way we are sure clamping forces are evenly distributed.
And that is more or less what I did - just without using the torque wrench. I tightened them up with a regular ratchet several times around and then used the torque wrench to set them on the final round (actually two rounds).
Keith Rucker - VintageMachinery.org Must have missed it, sorry my bad :-)
Great videos, lots of respect for your skill set. There's not that many can master all that knowledge.
Thanks for taking the time to reply. All the best to you & your family.
Your mystery port in the cylinder was probably originally fitted with an automatic spring loaded cylinder cock that would allow the condensate to escape during a boiler priming issue and also a safety over ride if the operator forgot to open the manual drain cocks on start up.
Interesting video!
Keith great vids, the border set screws are known as scotch keys, common in machine tools. Your reference to ground surfaces on the heads for no gasket is known as steam tight scraping, it's how I got Into hand scraping, learned it from an old timer whos long gone, and it's a true art form, scraping to fit and zero clearance, it's the epitome of fine scraping, no doubt 100 years of warp will have skewed the original surface. I've defaulted to copper kote in aerosol form for many such applications, I enjoy your videos, wish I had the patience and time to teach like you do. Keep up the good work!
not many hand sscrapers around any more.
Hi Keith. Love your site and videos. Been a machinist my whole life and love bringing old equipment back to life like you do. Great work your doing!
I hate to be "that guy" but I've seen too many injuries over the years. Please wear steel toes and long pants, and safety glasses. You will be better off. respectfully...thanks.
What a wonderful repair. I very much admire your thinking on how to repair this! Great job and thanks for posting this.
Thank you!
This is now my new favorite video, replacing the dovetail gear tooth replacement!
Thanks Shawn! That one is one of my most popular by the number of views. I hope this one does half as well!
Incredible video. Thanks for showing how to fix equipment by making parts.
What man with red blood running through their veins and arteries wouldn't like to do the same as you do. I love trains and to repaired them is just Epic.
It's a pleasure to watch a master at his craft.
You do some really good work. Lot's of variety and quality workmanship. Thanks for sharing!
I'm impressed. There were about 5 moments where I was expecting the video to end but it kept on going
That may have been because this video was shot over about five different days when I was able to work in the shop. Perhaps you could detect in my tone that I was going home for the day....
If this were broadcast the repair would have been cut down to 3 shots and the narrative would have been the 2 of you trying to pry the head off without *insert overblown consequence here* and you guys having a heated argument as to how to go about repairing it.
LOL - Which is why I HATE reality TV! I have actually been approached by a couple of "producers" trying to get me to do a reality tv show or two because of my RUclips channel. I always tell them NO WAY - way too much conflict and not enough about the stuff that is important....
Great video! Having worked extensively on a steam locomotive, they are simple but all the parts are heavy! Good job! We used hi temp RTV on a lot of parts too. It works.
You are right - in the grand scheme of things, they are pretty simple, but at the same time, there is so much mechanical going on, they are also somewhat of a marvel!
They are a marvel as there is no computer to back you up if things go wrong. And most of the training was OJT! Had a stuck blowdown valve once and that was frightening, even on an 0-4-0.
I've gotta say I really enjoyed this video. Keith, you have some wonderful toys (your tools) and your knowledge is great. Fun video to watch from one mechanic to another.
Thanks very much Keith...I was a kid back in the late 1940's so l remember these Locomotive very well....Once again thanks..!
Good repair. Most guys would have just pulled out the steam engine and put a 350 Chevy engine in it. Thank's again for preserving history.
LOL - that is what they have done with more than one. I can remember as a kid riding behind the little steam engine at Six Flags over Georgia. Then, about 20 years ago, they put an engine in the old boiler and mechanized it. What a shame....
Job very well done, thank you sharing this video.
The government is watching me. I recently started volunteering at a local museum, this museum owns and runs a Vulcan Iron Works train very similar to this one. I have had the wonderful opportunity to help with some yearly maintenance. I have never once looked up anything about steam trains on my iPad. I have never searched Vulcan Iron Works on any search engine. I mostly watch videos of small truck repair. I never have taken my tablet to the museum either. RUclips put this video on my recommended to watch list. I am quite freaked out.
outstanding... I just love to watch you work on this train.. Thanks boys..
Very nice repair Good camera & editing Pleasure to watch
Thank you kind sir!
Get a new optician man.
Another, well done, video. Thanks Keith.
Thank you John!
very good video. I love that you have a quick fix but always decide to do to take the time and do it right.
Thank you!
Really enjoyed watching this repair!
You are most definitely keeping yourself busy with projects Mr Rucker. :) Nice as always to find a new video from you.
Lots going on right now for sure!
Great fix Keith, the museum is lucky to have you around for your expertise.
I am lucky to have the museum to go and play at!
Love the shop and technology that still lasts and hopefully will.
Thanks!
Well done. Thanks for taking us along. Guy
Thanks Guy!
Nice and elegantly implemented repair. A thorough job .. but you already knew that! Thanks for the video!
Thank you!
Thanks Keith, great video. You guys DEFINITELY need to treat your shop compressed air!!
We have had that discussion...
Watching mill and lathe work is hypnotizing. : )
Look so exciting to be work on our old america train!
Options are great for this old machine.
"...and redo that whole hole..." I love it.
Very interesting repair thanks Keith , maybe someday I will come see the museum.
Would love for you to do that!
Really enjoy seeing you repair this old equipment. Always interesting.
(And as usual, you start to repair one problem and find another behind it.)
Very nice! I ran one of those knee mills for years. Brought back memories.
Great video love watching repairs on the old trains wish I could be there helping
Great "thinking out of the box", a great machinist' repair. Thanks for providing another super awesome video! You and your coworker did a wonderful job.
....13
Thank you sir!
I love anything to do with steam engines and this was a really good, in depth look at a practical small repair project - how things a done in a real-world situation. Fascinating!!!
Thank you!
18:05 Didn't love how that bit wasn't centered. You can see it tip up a bit on entry into the pilot hole. I'm sure everything works out in the end, though. Nice work! :-)
Yes he needed to drill the center drill deeper, I would have used a smaller drill first.
Keith, very nice. Got to see something I never would otherwise. Thank you!
Bob
My pleasure!
Keith it's not fair. I'm right in the middle of doing my work and then you put up a video with "Locomotive" in the title, which I can't resist. I have to drop what I'm doing and watch the video. Now I have to miss lunch to catch up before 5 o'clock. Can you wait until Saturday so all the guys who are addicted to your locomotive videos can get stuff done? ...... Seriously, it's a good video and you did a good repair. Last time I checked, they don't give bonus points for pretty repairs. I give it a grade of "D" for done and "F" for finished.
Sorry to interrupt you formerly productive day!
John Ferguson qeeww
Great video Keith - nice repair!
Nice job Keith - that head was heavy!!
Most things on a steam locomotive are heavy....
great creation of a proper boss for the fitting.
I thoroughly enjoyed locomotive maintenance, would love to see more.
Thanks!
I love watching you guy's working on those old steam engines.Keep them coming!
Thank you!
always interested in steam locomotives. thnx for sharing
Thanks!
Well it aint watch repair. I love to see the stuff you do. Long videos yet short and to the point. You have a knack for showing the right amount of the mundane to be sure we see how to do it. If you're having trouble removing/opening/taking apart something I need to see how you finally manage to accomplish the task. I hate when people skip over that stuff. I wander by your site every week or so and binge on the videos.
Thank you for taking the time and making the effort for me.
Thanks for stopping by and for the great feedback!
Those old drain holes headed out toward the bottom. I wonder if they were getting grabbed by saplings and getting broken off so they were moved to the front. I imagine the engine was run in some rugged country with tracks not used often.
Excellent job. Always good to see work on the Vulcan. ;)
That's an interesting theory, they would be in a vulnerable position underneath, especially if there is debris on the lines but wouldn't it be easier to fit something in front of them to clear the lines ?
I was thinking the same thing. I'm guessing that the loco was used in logging and that the original drain cocks got snapped off, probably several times. Most locomotives have the drains on the bottom of the cylinders. It also could be that the old holes just wore out or were stripped out. It's also easier to pull the heads than to work underneath the cylinders.
I am not sure whre the actual drain cock was located - if it was under it or up higher. I did not spend too much time trying to investigate the old system, but I am pretty sure that the casting was ported so that the cock was not underneath the cylinder.
I agree with the added screws, makes a better job. Nice video thanks.
Good approach, very well done. Good video.
Thank you!
Nice repair. I could almost smell the cast iron chip odor whist you made the lathe cuts. The first year or so on the job it seemed all I made was cast or ductile parts. Thanks for the share. All best.
I am one of those strange guys who actually likes working with cast iron!
The work looks great.
Nice repair Keith.Funny how we were just talking about cast vs steel.
Thanks!
You do great work Keith !
Thank you!
Great repair, wouldn't mind seeing the rest of the maintenance on her!
nice repair thanks for filming it
Thank you for watching!