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7410 - Test run at scratch built injectors


alanbuttler

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I'm back in Wales for a few days and to keep up the momentum of progress I figured I'd set myself a small project, something that doesn't take up too much space or need too many tools - making some injectors to replace the whitemetal ones with the NuCast 74xx. By the time I'd packed the reference books, tweezers, pliers, components, lamps, soldering iron etc I might as well have brought the whole tool box, but that's another matter.

 

Whitemetal kits and etched kits are completely new territory for me, so for about a year before I bought a soldering iron I read, read and read so more. Not that it changed much, I still didn't feel confident enough to even open the wrapper on the Dean Goods chassis, certainly not the High Level Pannier I'd bought eagerly at ScaleForum months ago, still sat neatly packed in its box... time was the main factor, I needed a clear head and some hours set aside to have a go. Now I've got a bit more free time there are no more excuses left. Soldering iron has been bought, Whitemetal kit attempted. No turning back now!

 

I'd first heard of Iain Rice's Building Whitemetal Locomotives and Etched Loco Construction through Geoff Forster's blog Chronicles of Penhydd and I managed to find them both very cheaply second hand. As well as explaining the whole process extremely clearly and with some humour from time to time, it's the level of scratch built detail that really captured my attention - vacuum pipes (with pipe couplings!), backheads, washout plugs and so much more. It was the injectors that caught my eye though as these are nearly always poorly reproduced in plastic. So here goes, an attempt at creating one of these small Iain Rice masterpieces.

A few months ago the components were collected:

  • 1/16" Brass Capilliary Tubing for the Injector body
  • 0.75mm Copper Wire for the steam and water pipes
  • 1mm Copper Wire for the Top feed and Overflow pipes
  • 16BA and 14BA washers and nuts for the fittings and valves

15093185824_9e89e6e6d9_z.jpg

74xx Scratchbuilt Injector components by CAMBRIAN AL, on Flickr

 

Before starting however I realised I had no idea what all these mysterious pipes actually did. So a bit of reading up was the first job and thankfully the Bluebell Railway have a full description of the process, documented when they replaced the injectors on 9017:

Quote

Steam from the boiler, and water from the tank or tender, pass through a stop valves (taps) controlled by the fireman. When he wishes to increase the level of water in the boiler he turns on the water and steam valves.

Initially water passes into the injector by gravity, where it lifts the hinged combining cone flap, pushes down the overflow valve and runs out of the overflow pipe onto the ground. When the steam valve is opened, a jet of steam escapes from the steam cone. This jet has a high velocity, which it imparts to the surrounding water. At the same time the cold water starts to condense the steam jet. During condensation the volume of the steam is vastly reduced, so a partial vacuum is formed which (a) draws more water from the tank, (b closes the overflow valve, and © shuts the hinged combining cone flap. The mixture of condensing steam and cold water continues to gain speed as it travels through the combining cone. It emerges from the small end of the combining cone as a jet of hot water. It then travels across the gap and into the divergent delivery cone. Here the speed of the jet is reduced, but its pressure is increased sufficiently to lift the delivery clack (non-return valve) and flow into the boiler

To help get my head around the various pipes, valves and their purpose I put a 3D model together in Sketchup. This is based on the 74xx, though there is an additional thinner pipe from the water inlet valve which goes into the cab - I'm guessing this is how the fireman controls the water inlet from the tanks?

 

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74xx Injector - Sketchup design for possible 3D print by CAMBRIAN AL, on Flickr

 

Just getting the thing drawn on paper was a challenge, its the kind of device that no matter how many times I look at it I spot another pipe I'd not seen before, or then looking at it in reverse, on the opposite side of the tank might as well be the first time I've seen it. A few sketches and the 3D model helped though and I think I've now grasped the concept!

 

For a test I've started out with just the basics - fitting 2 types of wire to the capillary tube and fitting a washer and nut. Straightforward enough I thought, before I started to employ every tweezer I owned and still needed an extra hand. After a while of remelting all the solder and the whole thing falling apart for the 10th time, I switched tactics - drown the whole unit in flux, melt the solder onto the new item to introduce and quickly jam it in place before the solder hardens.

 

Or alternatively, tomorrow I'll try to do the whole lot in a 10th of the time with super glue (I'm sure it will still be a challenge though!)

 

Or, I'll 3D print the body and still use the wire for piping...

 

15689404506_d48cc44a4e_z.jpg

74xx Scratchbuilt Injector test by CAMBRIAN AL, on Flickr

 

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74xx Scratchbuilt Injector test by CAMBRIAN AL, on Flickr

Edited by alanbuttler

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Good progress there, Alan. Before giving up on soldering, you might try making a simple jig -- just pins in a block of wood -- to hold the various pieces of wire in place as you add each part. Maybe also use a high temperature solder (188 or above) for the core parts and 145 or lower for the parts added later.

 

That said, I have to ask why not just use the Alan Gibson cast brass injectors. They are a good representation of this particular type and can be fairly easily modified to match the slightly different arrangements on some other GWR tanks.

 

Nick

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Alan, I admire your tenacity and bravery to tackle such a small item to be soldered. I agree with the use of jigs to hold pieces together while soldering or gluing. I was recently using and old cork sanding block for that purpose though what I really wanted was some polystyrene packing material.

 

Also, I am not sure if you did this or not, but soldering longer pieces of wire which are then trimmed off may help. In my case my fingers definitely need that kind of assistance!

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If you want I can post a couple of pics which show the detail of an injector and the relevant part of the inside of the cab on a 1366 although it has the clacks on the backhead instead of a top feed so the pipework to them follows a different route.

 

On yours - if you want super accuracy you need a straight rod (not a pipe with a bend in it) from the cab to the water valve just below the tank.  On the 1366 this rod is above the feed to the clack so doesn't need to be cranked or bent but the 74XX could be different.

 

Also the steam feed pipe and the water feed into the injector are opposite each other and not at an angle - steam at the top and water coming in from underneath and it seems to be exactly the same on all the 74Xx pictures that I can find showing a decent view of an injector although the route of the steam feed from the cab front sheet varies.

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Good progress there, Alan. Before giving up on soldering, you might try making a simple jig -- just pins in a block of wood -- to hold the various pieces of wire in place as you add each part. Maybe also use a high temperature solder (188 or above) for the core parts and 145 or lower for the parts added later.

 

That said, I have to ask why not just use the Alan Gibson cast brass injectors. They are a good representation of this particular type and can be fairly easily modified to match the slightly different arrangements on some other GWR tanks.

 

Nick

 

Cheers Nick for the advice, the higher melt solder and jig I'll give a go.  I've just looked at the Alan Gibson ones on your saddle tank and I see what you mean, they do look pretty good.  I guess I'm using this as a skills developing project so even though I'll probably end up ordering the AG injectors I'll persevere.  It all helps with brushing my skills up before tackling something like the 78xxx with all its appendages!

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Alan, I admire your tenacity and bravery to tackle such a small item to be soldered. I agree with the use of jigs to hold pieces together while soldering or gluing. I was recently using and old cork sanding block for that purpose though what I really wanted was some polystyrene packing material.

 

Also, I am not sure if you did this or not, but soldering longer pieces of wire which are then trimmed off may help. In my case my fingers definitely need that kind of assistance!

 

Thanks, I'll give the longer bits of wire a go :)

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If you want I can post a couple of pics which show the detail of an injector and the relevant part of the inside of the cab on a 1366 although it has the clacks on the backhead instead of a top feed so the pipework to them follows a different route.

 

On yours - if you want super accuracy you need a straight rod (not a pipe with a bend in it) from the cab to the water valve just below the tank.  On the 1366 this rod is above the feed to the clack so doesn't need to be cranked or bent but the 74XX could be different.

 

Also the steam feed pipe and the water feed into the injector are opposite each other and not at an angle - steam at the top and water coming in from underneath and it seems to be exactly the same on all the 74Xx pictures that I can find showing a decent view of an injector although the route of the steam feed from the cab front sheet varies.

 

That would be great if you didn't mind, it would be interesting to see what happens inside the cab.  I'll take this test piece apart tonight and have a go with a jig with the parts fitted as you describe.  Once I've got my 3D printer set up it will be interesting to see how it handles something as small as the injector body, if successful it will just need holes for the various wires drilling.

 

Cheers for the feedback gents, much appreciated!

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