2/26/2010, last updated
Wayne Godshall (http://godshallscustommachining.com/)
made the boiler. The drawings in the Boiler Design page match the
boiler. This page shows photos of the boiler
as well as photos of the fabricated firebox door, the water glass,
pressure gauge and steam manifold.
The photo above shows the boiler side. The fire pan is in place in
this and the next photo.
|This is the boiler back.
The round opening for the firebox might not be appropriate if
one is burning coal.
The two holes in the upper portion
are stay tubes which run to the front tube sheet.
The two holes in the mud ring are cleanouts.
|This in the front tube sheet. The 31
tubes are 5/8" OD copper (1/2" copper pipe).
The large hole in the top is for a compression fitting that
seals around the throttle output pipe. The two smaller
holes in the upper part are the stay tubes that tie the front tube sheet
to the boiler back.
|This is the inside of the fire box ---
not very exciting.
|This angle of the fire box is a little more
interesting in that the flues are visible.
The boiler probably weighs between 100 and 150 pounds. The
engine hoist pictured above comes in handy to install and remove the
boiler making an unpleasant task quick and easy.
Firebox Door: The firebox door was constructed
over a period of at least a year and it was not one of my favorite
projects. The actual construction was fairly
straightforward. The only complex part is the unusual shapes
involves. The following photos should help with understanding the
shapes and how they all go together.
The handles were made much larger than shown in the design drawing and
very much out of scale as are the engineer's fingers. The base is
attached with 4-40 screws into 1/8" deep holes into the boiler back
head. The pair of (#2) screws in the boiler side of the door
serve as stops for the damper plate.
|Water Glass: The water
glass pictured at the right was machined from 1" square bar
stock by Wayne Godshall. The top nut is threaded 9/16-18.
There is a 1/4" OD brass tube inside the nut that has a 1/2"
diameter flange below the nut and 1/4-40 threads above the nut.
The glass is sealed with 3/8" ID- 1/2" OD Viton O Rings at each
end. Those 14 screws are #2-56 and only decoration.
The two valves screwed into the boiler are 1/4" and the blow
down valve is 3/16" Note the positioning of the valves.
Each valve and pipe to the boiler can be tested by closing the
other boiler valve and opening the blow down. The
differential pressure across the water glass in only a few
ounces so the pipes & valve can be easily plugged by a bit of
debris. Hence, I try to remember to test the water gauge
plumbing each time I fire up.
Steam Plumbing: The initial pan was to have a
separate webpage section for the steam plumbing. However, I since
decided to to describe the steam manifold here and to describe the
individual runs from the manifold with the description of the appliance
on the other end.
The photo above shows the plumbing from the steam dome to the steam
manifold. The tees, 1/4" valve and compression fittings are
standard plumbing fittings from McMaster-Carr. Note that the
valve can cut off the whistle and the steam manifold for
maintenance. The pressure gauge is before the valve so that
it can't be cut off.
The manifold is made from a 4" length of 1/2" square brass bar stock.
It was drilled lengthwise and the ends tapped 1/4-40. Three holes
were drilled and tapped 3/16"-40 in the top. (There is room for
additional ports if required.) The stub out the back is 1/8" NPT.
Two 6-32 studs extend out the front. The studs and stub out the
back were silver soldered to the manifold.
|The manifold is attached to the support plate
(1/8" X 4' W X 4.754" H HRS) via the two studs. The stay
tubes were tapped 7/16-40 and fitted with 7/16-20 to 6-32 brass
bushing. The pair of screws near the bottom of the
support plate are into these bushings.
The support plate
is very sturdy with the screws in the bottom and the tube to
the steam dome steadying the top. It is a handy place to
hang the pressure gauge bracket and a bushing for the throttle
|Feed Water Heater:
The coils of 1/4"
tubing shown at the right are the feed water heater which is
described in the Water Plumbing section. It is
mentioned here because the coils appear in the background of
some of the photos of the inside of the smoke box. Water
enters the heater through the side of the boiler tube in the
lower right of the photo. This is on the smoke box side of
the front tube sheet so this is unpressurized. The output of the
feed water heater is via a 1/4" tube compression to 1/8"
NPT fitting on the middle right of the photo. This fitting
goes screws into the front tube sheet. The two
bolts are 3/8"-24 threaded into the ends of the stay tube ---
it's a sloppy fit but OK for these light duty supports.
This is a good place to stop. The story continues on the
Construction II page where the smoke box, throttle and superheater are discussed.