January/February 2018 production photos

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January/February 2018 production photos

Post  craig@STW on Fri 05 Jan 2018, 4:11 pm

hello and welcome to 2018, there was no production pics at the end of last year because we all finished early on the friday and as we were having a factory xmas clean-up, i didn't even have time to think.

so this is where we are at at the end of this week. i know i said we had seen the last of the Lyka kits for a bit but due to the nature of the water tanks, the manual guys have already started bending the sheet work...



and a new addition to the water tanks are internal baffles...



on the machines, we now have the six inch foden smoke-boxes as complete units...



and the final holes have been drilled...



i have also been working on the foden 6inch boiler cradle...



and the front axle assembly...





and swivel hubs...



BU roller 2nd shaft tubes are done...





i have now managed to finish the small batch of showmans rear axle tubes for the couple of customers who had these outstanding. these will be ready to send out next week. sorry for the delay but due to the accuracy and power needed on the bore holes we had to wait for our big machine to be available to finish these...



on one of the lathes, roadloco smoke-box door rings...



and work has started on 100's of showmans rear wheel spokes. we counter sink these on the machines as it takes about 40 seconds to do 4 spokes...



and waiting to go on the large machine next week, 3 pallets of showmans rear wheels to have the spoke holes drilled...



Last edited by craig@STW on Fri 02 Feb 2018, 3:48 pm; edited 1 time in total
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Re: January/February 2018 production photos

Post  Mark the spark on Thu 11 Jan 2018, 8:19 pm

Hi Craig
Any update on last 2 showmans kits?
Thanks

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Re: January/February 2018 production photos

Post  craig@STW on Fri 12 Jan 2018, 3:48 pm

all i can tell you on the last two showmans kits is that the one motor that was checked was unsuitable and another has been ordered and is on the way.

well this weeks photos do seem to be very much like last weeks, its just that things have moved on a bit or the model has changed.

the showmans rear wheels are on the machine and being drilled...



and with all the spokes for them countersunk we are now working on the spokes for the new batch of wagons (this is just a very small selection of the 100's of spokes we have had to do)...



and whilst on the subject of the wagons, this material if waiting to be turned into the hubs and inner and outer covers...



having finished the 6inch foden smoke-boxes, we are now working on a batch for the road-locos...



and the smoke-box rings...



the 6inch foden front cradle is on its last opp...



the manual section are working on the Lyka water tanks now...



and most of the lathes are working on the various bushes that go into them. one part thats a little more interesting is the filler cap, this should look even better next week when i mill the outer edge...

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Re: January/February 2018 production photos

Post  craig@STW on Fri 19 Jan 2018, 3:56 pm

this weeks photos  Very Happy

to carry on from exactly where we left off last week, here is the finished lyka water tank filler cap after final milling...





all the showmans rear wheels are drilled and as usual we always put one together to make sure everything fits...



the other wheels we are working on are the smaller traction wagon wheels...



the spokes...



the hubs...



and inner hub covers...



in this photo you can see the various stages of the hub machining process, from solid to (almost) finished...



on the big machine... heavy machining cutting a 6inch foden chassis bracket from soild...



also this week some valve glands...





and as usual, i have tried to include something from the welding bay.

most of this weeks work has been on the lyka water tanks and Harry is now back on boilers, but i did manage to find something a little different. showmans roof stays having some short lengths of studding welded onto them...

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Re: January/February 2018 production photos

Post  craig@STW on Fri 26 Jan 2018, 4:01 pm

this weeks photos...

firstly, news on the showmans generator kit. Ian is currently investigating the modification of a car alternator. seems like a good plan to me, if its good enough for a car then i would think it would work on a model, but what do i know ??? Very Happy



in the machine shop, we are still cutting those large 6inch foden chassis brackets from solid. these things are big (if you compare them to the scrap cylinder blocks in the background) and most of the billet is cut away to be honest. the first side alone takes 18 mins to cut.



nearly done now...



we are also working on the second showmans rear hub/wheel kit...



and with the wagon hubs and inner and outer covers done we are now onto the hub caps...





and the rims arrived today, and will be on the machine on monday for drilling
(there are more than these as they are being un-wrapped as i type  Laughing )...



where you have hubs you need an axle, among this lot we have wagon and water cart axles...





and not everything we do is complicated. here we are simply machining a radius on a ready made bush...



and in the welding bay... the Lyka water tanks are still being welded !!! most are now done and have been leak tested. And after having the extractor system serviced Harry can now concentrate on the latest batch of boilers...

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Re: January/February 2018 production photos

Post  Mark the spark on Fri 26 Jan 2018, 4:27 pm

Car alternator is a good idea they can make lots of power but require 12volts to kick them into life

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Re: January/February 2018 production photos

Post  LiveSteam on Fri 26 Jan 2018, 6:45 pm

Mark the spark wrote:Car alternator is a good idea they can make lots of power but require 12volts to kick them into life

That was my thought, they often will start generating on their own but without a 12v battery for a base line it can kill the regulator off pretty quick. Although they do have to go round a fair few lick and I'm not sure the showmans will be able run at the speed it needs to ?
I might be tempted to investigate generators that wind power folks use ?

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Re: January/February 2018 production photos

Post  Mark the spark on Sun 28 Jan 2018, 12:18 pm

If your are looking at alternators then I would surgest looking at ones fitted to diesels as they often have a shaft or output to drive a vacuum pump for the brakes and you should be able to use that for the exciter drive
Mark

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Re: January/February 2018 production photos

Post  Ian on Mon 29 Jan 2018, 9:43 am

LiveSteam wrote:
Mark the spark wrote:Car alternator is a good idea they can make lots of power but require 12volts to kick them into life

That was my thought, they often will start generating on their own but without a 12v battery for a base line it can kill the regulator off pretty quick. Although they do have to go round a fair few lick and I'm not sure the showmans will be able run at the speed it needs to ?
I might be tempted to investigate generators that wind power folks use ?

That's the avenue I am currently investigating firstly 24V alternator so we can go slower to get 12V and a rare earth permanent magnet rotor so we don't need to excite it with a battery, just like the wind power people but without a regulator, output will be governed load and by RPM.
The diameter of the flywheel and the diameter the generator drive pulley will push up the RPM at the generator rotor.

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Re: January/February 2018 production photos

Post  LiveSteam on Mon 29 Jan 2018, 8:07 pm

Ian wrote:
LiveSteam wrote:
Mark the spark wrote:Car alternator is a good idea they can make lots of power but require 12volts to kick them into life

That was my thought, they often will start generating on their own but without a 12v battery for a base line it can kill the regulator off pretty quick. Although they do have to go round a fair few lick and I'm not sure the showmans will be able run at the speed it needs to ?
I might be tempted to investigate generators that wind power folks use ?

That's the avenue I am currently investigating firstly 24V alternator so we can go slower to get 12V and a rare earth permanent magnet rotor so we don't need to excite it with a battery, just like the wind power people but without a regulator, output will be governed load and by RPM.
The diameter of the flywheel and the diameter the generator drive pulley will push up the RPM at the generator rotor.

Sounds very much like my Hornet wind generator, which is basically a regular vehicle alternator stripped out with a rare earth rotor fitted.

Its one of these https://www.ebay.co.uk/itm/Wind-Generator-PMA-G-Generator-alternator-UK-supply-for-serious-wind-turbines/371642671583 although I didnt pay that for mine but then I bought mine 10yrs ago now, puts out crazy amounts of juice Cool


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Re: January/February 2018 production photos

Post  craig@STW on Fri 02 Feb 2018, 3:59 pm

photos from this week...

the big machine has finished blocking out the first 6inch foden bracket...



and is now onto the second...



with the traction trailer hubs done we are now on the ones for the normal driving wagon...





the roadloco smoke-boxes have had their rings welded in and are ready for machining...



in the welding bay, fire boxes are under construction...



and the welded boilers are having their tubes fitted...

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Re: January/February 2018 production photos

Post  craig@STW on Fri 09 Feb 2018, 3:58 pm

this weeks photos. we seem to be stuck on the same few jobs at the moment but its really because of quantity and size of parts that things are taking time.

the second of the 6inch foden chassis brackets are just about done...



wagon hubs are done...



but now we are on the inner and outer covers and hub caps...





the roadloco smoke boxes are now on for drilling...



next on the machines will be these small 2inch water fillers, they just need the mounting holes drilling...



on the live-tooling Hass machine we have lyka fuel tank filler caps...





and the fuel tanks are being welded now. note the extra sump area for any unwanted bits of dirt...



the outer tubes for the lyka boilers have arrived...



these photos show the general arrangement of the water tanks and boiler...





and our weekly look in the welding area... well to me this looks exactly like a photo we had about 3 weeks back but Harry assures me it is a completely different boiler near to completion  scratch  Rolling Eyes  Laughing ...

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Re: January/February 2018 production photos

Post  craig@STW on Fri 16 Feb 2018, 3:55 pm

this weeks photos.

the wagon hubs, and inner and outer hub covers are done and we now just need to finish drilling the hub caps...



and just when you think you are coming to the end of the wagon wheels... the rims for the rear arrive !!!



so after simple drilling...



and a test fitting, they are ready to go...



road-loco smoke boxes are finished on the 4th axis, but then we pop out the door rings and drill the hinge mounting holes and mill the dart bar slot...



and the smoke-box to boiler flange is milled to size...



the large machine is drilling Showman's horn-plates...



and the 6inch foden rear axles are coming together...





in the welding area its all hands on deck to get the lyka tanks finished, this is the fixing of the mounting brackets...



and the three tanks in position in the chassis...

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