Update 25/2/16. By Ian, Matt and Simon

Bumper update from the last couple of weeks.

D7017 visited Minehead on Saturday 20th for a routine annual underframe examination.
The loco will be making a guest appearance on the Sunday of the Somerset and Dorset Steam Gala. It will
work a "demolition train" replicating the actual demolition trains that broke the railway up. The loco is also
making a visit to the St Philips Marsh Open Day on May 2nd.

D7018 work continues on the loco under testing. Some photos below showing the excellent high quality work
that has been done on the locos battery box and transmission testing

D9518 Simon writes.
Dave Hammond has made a sterling effort in cleaning and preparing the frames under the generator plate,
still a bit more to go, but it looks a lot cleaner under there already.
The spacer to frame rivets appear not to have worked at all - thank goodness.
Terry and Mike E fettled a new cover plate for the Hunslett reversing shaft locking pins.  This was machined
by Ryan earlier in the week.

Inverlane engine for D9526
Terry, Mike E and Gordon made up some new brackets to support the coolant pipe that runs across the
front of the engine and through the Turbo bracket.

Cameron and Simon started 'Winter' Maintenance, with greasing the brake rigging, cardan shafts, and
examination of the reversing gear. Winter maintenance activities pictured below.

D6566 Ian writes.
On Saturday 13th February with all of the cylinder heads now in position and leak checks successfully
passed, the time had come to torque the nuts up to their specified setting.

SDDT at Buckfastleigh have kindly loaned us their 5x torque multiplier which is better than the basic one we
have at Williton as it has an arm that holds a second socket to pick up on one of the other nuts for reaction
This is of course used in conjunction with a torque wrench. So with Dave L and Leroy assisting, we decided
to start on No.8 head.
The first six of the eight nuts pulled up to the required 750 lb-ft without any problems but when we came to
the last but one Leroy thought it didn’t feel right as the tightness was not increasing.
So we looked underneath the head and it was apparent that the stud appeared to be pulling out of the block
and had done so by about 1.5mm before we had stopped.  Not good news.
As it was necessary to remove the head again to investigate the issue but the gantry crane could not be
moved into position that weekend due to being in use on D7018, we decided to continue with the nut
torqueing and re-started at No.1 head. By the end of Saturday we had successfully completed No.1 to 3
heads without further incident.

On the Sunday, I continued first on my own and then with Andy P assisting, and we managed to complete
torqueing up to No.7 head plus proving all the remaining studs on No.8 head so it would appear it is only the
one stud that has failed. I fact had we originally started at No.1 head it would have been the second from last
stud of the lot that failed!  But having done that we fitted the rocker assemblies to No.1 and 2 heads which
are the ones acquired from Romania and set up the tappet clearances thus proving there are no
compatibility issues with the metric threads.

On Saturday 20th February No.8 head was lifted off and the stud issue investigated. This confirmed that the
stud was indeed pulling out of the block and the slivers of metal lying around suggested that the block
parent thread was failing. Despite that, and both myself and Paul F on a large pair of stillsons, the stud still
took some shifting!

But when the stud was eventually extracted, it was apparent that it had broken some considerable time ago
about half way down inside the hole. As only the top portion of the thread was taking the load, it had
therefore failed when we put the stress back on to it. This has basically destroyed the top half of the parent
thread and leaves a remnant of the stud stuck in the bottom.
Normal practice in this case is to drill and tap the hole out to the next size and fit an oversize stud.
A jig to do this is now being sought as well as a replacement stud, few and far between nowadays.

So if anyone has the necessary tooling and would be prepared to lend it, and/or an oversize Sulzer stud for
sale, please get in touch with us. It will be most appreciated. Thanks.

But returning to Saturday, Paul and me then installed the rocker assemblies on No.3 to 6 heads and set up
the tappet clearances. We have left No.7 head clear for the time being just in case it also has to be removed
for access to the repair. So one step forward, two steps back at the moment.