Spa Valley Railway

Spa Valley Railway, West Station, Royal Tunbridge Wells, Kent, TN2 5QY
Telephone: 01892 537715
Email enquiries@spavalleyrailway.co.uk

Overhaul Of LB&SCR Terrier 'Sutton'

'Sutton' arrived on the Spa Valley in April 2004, from the Kent and East Sussex Railway where it had previously operated in preservation, but for the last 10 years had sat on display in Tenterden Town Station yard. The overhaul of this engine has been placed in the hands of the engineering team at the railway and will be carried out over the next few years. Regular updates of progress will appear here.

JANUARY 2008 - OVERHAUL UPDATE AND SUMMARY

The frames for Sutton are lifted in preparation for placing on its accommodation bogies in late November - Photo M. Dives Although no update here for almost a year, a lot of work has gone into this engine. Sutton spent most of 2007 outside in the yard where it its frames were sandblasted and painted to keep them protected. In November 2007 the frames were placed back in the shed where the covered accommodation has sped up the painting of the frames and the application of top coats is already advanced.

Left:- The frames for Sutton are lifted in preparation for placing on its accommodation bogies in late November - Photo M. Dives

The wheelsets were sent away in mid-January to the South Devon Railway, where they will be turned on their wheel lathe, before returning for work to commence on their axleboxes around mid-February. Sutton's frames sit on the accommodation bogies outside the shed in late November - Photo M. Dives

In late 2007, the contract was let for the machining of the new cylinder block castings. Because the chosen company is so busy, there is a large lead-in time for this job, so the castings will not be going away until towards the end of 2008.

Right:- Sutton's frames sit on the accommodation bogies outside the shed in late November - Photo M. Dives

Other work has concentrated on stripping the old cab structure down in preparation for the roof and other components to be repaired and rebuilt.

This is the progress on the frames in early August 2007. Most of the frames had been sandblasted by this point and a lot was already in an undercoat. This view shows the space left by the removal of the cylinder block - Photo M. Dives The machine shop have also been busy manufacturing components for 'Sutton's suspension. This includes making new pins and bushes which should see uniform components on the engine, and make replacement of any parts in the future, a lot easier.

Left:- This is the progress on the frames in early August 2007. Most of the frames had been sandblasted by this point and a lot was already in an undercoat. This view shows the space left by the removal of the cylinder block - Photo M. Dives The frames in late March 2007 showing the progress made with the sandblasting inside the frames - Photo M. Dives

Right:- The frames in late March 2007 showing the progress made with the sandblasting inside the frames - Photo M. Dives

So almost 4 years after Sutton arrived at the Spa Valley and 3 and half years after the overhaul begun, here is what work has been undertaken on the engine:

Locomotive fully stripped down
Frames completely shot-blasted and painted
The old cylinder block removed
New cylinder castings have been purchased and the contract tendered for their machining
The wheels have been sent away for tyre turning
All six springs have been sent away and overhauled
Components for the engine's suspension have been manufactured in our own workshops
Frame sections have been replaced
The cab has been dismantled in preparation for repair and reconstruction
The boiler assessed and the work identified to gain it a new 10 year overhaul
Many of the locomotive's fittings have been overhauled and placed into store

There is still a lot of work needed to be undertaken before 'Sutton' steams again and money towards the overhaul is still needed, so please keep donating.

MARCH 2007 - OVERHAUL UPDATE

The big piece of news is the removal of the cylinder block from the frames. This follows a lot of work into removing the rivets from the frames to enable this to happen. This involved drilling some out and also melting others out, which has been a fairly laborious, lasting a number of weeks. The block itself has now been placed on top of the engine until space elsewhere can be found for it.

A view between the frames with the cylinders removed, and placed on top of the engine - Photo M. Dives A view of the front end of the cylinders which have been sat on the engine's frames - Photo M. Dives

Above Left:- A view between the frames with the cylinders removed, and placed on top of the engine - Photo M. Dives
Above Right:- A view of the front end of the cylinders which have been sat on the engine's frames - Photo M. Dives
Below:- A view of the rear of the frames showing the glands where the piston rods and valves spindles slide in and out - Photo M. Dives

A view of the rear of the frames showing the glands where the piston rods and valves spindles slide in and out - Photo M. Dives

Work will now concentrate on repairing the rear end of the frames and drag box area, as well as cleaning them up, ready for sandblasting and painting. Once this is completed, the frames may then be placed in the shed so that assembly and fitting of components can commence.

Also the boiler has had an assessment and found to be in good condition and is likely not to require too much work. A final report is awaited.

JANUARY 2007 - OVERHAUL UPDATE

The rivets are drilled out using the mag-mount drill. Around half the rivets have been removed using this method - Photo M. Dives Since the frames were lifted late last year, work has progressed on a number of fronts. All the axleboxes and springs have all been dismantled and steam cleaned. The axlebox bearings have had all the white metal run-out and now await soaking in the caustic bath, which was finished in late January.

Whilst the caustic bath was being completed, work has continued on the frames in a number of areas. Drilling out the rivets that hold the cylinder block in the frames, has commenced which will also involve splitting the frames to free the block. Therefore some of the rivets that hold the front buffer beam to the frames, have been removed.

Left:- The rivets are drilled out using the mag-mount drill. Around half the rivets have been removed using this method - Photo M. Dives

The new angle irons fitted to the rear area of the locomotive. This supports all the cab floor. A frame stretcher, which provides the dragbox for the coupling has also been removed for attention - Photo M. Dives

The rear area of the frames have also received some attention. Angle irons which support the cab floor, have been drilled and bolted to the frames. Other work has been carried out on some of the frame stretchers too.

Part of Sutton did return to service late in 2006. Two springs were lent to the Isle of Wight Steam Railway to be fitted to Terrier 'Freshwater' so that it could appear at the Bluebell Railway's Terrier Weekend. These were sent away for overhaul after use, and returned to the railway ready for re-fitting to Sutton, in early January.

Above Right:- The new angle irons fitted to the rear area of the locomotive. This supports all the cab floor. A frame stretcher, which provides the dragbox for the coupling has also been removed for attention - Photo M. Dives

OCTOBER 2006 - FRAMES LIFTED AND NEW CYLINDERS!!!

Sutton's frames are carefully lowered and positioned onto blocks of wood in the middle of the yard - Photo T. Christian News on two major areas this month!!! In early October, the engine was towed out into the yard and the frames were lifted from the wheelsets, and placed in the yard. Here they will be cleaned and painted and the cylinder block will be removed. The wheels have returned to the shed where they have been stripped down further and all the components steam cleaned.

Left:- Sutton's frames are carefully lowered and positioned onto blocks of wood in the middle of the yard - Photo T. Christian

On the other major front, after months of negotiations, the railway has purchased a set of newly cast cylinders from the Bluebell Railway. It was decided that the old set of cylinders were beyond repair and that a new set would be the best option. These castings have been paid for entirely by the money YOU have donated to the fund over the last couple of years. Quotations are now being investigated for getting the castings machined. The three main components of Sutton altogether. The frames and boiler sit in the yard with the wheelsets alongside - Photo M. Dives Some of the money is available to start this, but we still need to raise more to get the machining underway early next year. Work continues on removing the old cylinders.

Left:- The three main components of Sutton altogether. The frames and boiler sit in the yard with the wheelsets alongside - Photo M. Dives

The new cylinders sit in the yard at Tunbridge Wells West the day after they were collected from Sheffield Park. They now await machining - Photo M. Dives

Right:- The new cylinders sit in the yard at Tunbridge Wells West the day after they were collected from Sheffield Park. They now await machining - Photo M. Dives

SEPTEMBER 2006 - BOILER LIFT AND PROGRESS

Sutton's boiler is eased out from the frames in late July. It can now be seen sat in the yard awaiting final preparation prior to a thorough assessment - Photo M. Dives A major step on the restoration front was the lifting of the boiler, from the frames, in late July. This has now been placed in the yard to await final inspection. Prior to this, the firebox requires grit blasting so that dye-penetrative testing can be carried out on radius and joints, so that a comprehensive report can be made on this aspect of the overhaul.

Left:- Sutton's boiler is eased out from the frames in late July. It can now be seen sat in the yard awaiting final preparation prior to a thorough assessment - Photo M. Dives Sutton sits with visiting Terrier 'Martello' on July 16th, offering visitors the chance to see what will be on offer upon the completion of her overhaul - Photo S. Pay

On the frames, more concrete has been broken out from the smokebox saddle area to reveal the rivets holding the cylinder block in. More need to be removed so that the cylinders can be lifted out. To get at some of these rivets, the frames will need to be lifted from the wheels. In the last week or so, the springs have been freed from the frames. This may be followed by the frames being lifted off of its wheels. Talks are continuing with regards to acquiring a new cylinder casting. At the moment there is little to report but we hope to make some announcements shortly.

Right:- Sutton sits with visiting Terrier 'Martello' on July 16th, offering visitors the chance to see what will be on offer upon the completion of her overhaul - Photo S. Pay

In early September, the frames received a thorough steam clean to prepare for the strip down of the final frame components.

MAY 2006 - GENERAL UPDATE

Left:- Sutton's boiler after it was jacked out of the frames. At this stage, painting and needle gunning were still underway on the boiler - Photo M. Dives

May saw a number of jobs carried out. The boiler has been jacked out of the frames and the needle gunning and painting has been completed. Following a washout to remove the loose scale, a full inspection of the boiler can now be planned. A quick preliminary suggests the boiler is not in bad condition, although a full inspection and dismantling can reveal hidden nasties!

The smoke box and chimney have also been cleaned off and a coat of primer applied. It's amazing what a coat of paint can do, and to the average visitor, the boiler could be taken as being finished and ready to go back in. If only! The boiler is now awaiting a lift by the large crane, but this is currently out of service, so it is being put back for the time being. This doesn't mean that work has stopped though.

For anyone who is too impatient to wait and ride behind Sutton, they can sample Terrier action on the Spa Valley until the middle of July. Sutton's sister 'Martello' will be hauling trains on the railway at weekends from June 10th until 16th July.

Right:- Painting progress on the boiler. Project leader Dave Joyce is seen applying the first coat of primer to the smoke box on the 28th May - Photo M. Dives

APRIL 2006 - LOTS OF PROGRESS!!

Although progress appears to have slowed, a lot has gone on out of site on the engine. In early January, project leader Dave Joyce, completed the removal of the boiler tubes, a job he did solely on his own. He then freed the boiler at the front end, which means a boiler lift is possible, but the approximate time is unknown right now.

Right:- A view inside Sutton's smokebox showing the tubeless boiler. If you look carefully, you can make out the firebox tubeplate through the tube holes. The smokebox door has been removed and placed into storage - Photo M. Dives

Dave has also removed the remainder of the valve gear, the slide bars and pistons. This all means that the frames should be able to be lifted soon after the boiler, to release the wheelsets. A full assessment of the work required will then be made.

Other work carried out in late 2005 included the removal of the cab floor for renewal, along with the angle iron supports by Tim, who drilled 70+ rivets to free these items. The back end of the engine is now stripped down to its furthest state, and it’s hoped that a start on rebuilding this area will begin in the coming year. Tim has also been working on removing the dome cover studs which require drilling out.

Left:- The rear end of Sutton showing the progress made here. The floor on the engine is loose and has been removed from the engine, prior to being placed back temporarily for storage. All the firehole door apparatus has been removed too - Photo M. Dives

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