Shay Plumbing VII - Engine
Steam & Exhaust Pipes
Nelson Riedel Nelson@NelsonsLocomotive.com
Initial: 11/18/03 Last
Fabricating the engine steam and exhaust pipes seem to be the last items
that require moving the boiler around; hopefully when these are completed the
boiler can be secured and I can move on to less weighty subjects.
|Cass No 5: Some of the photos from Cass were examined
before starting this part of the project. This is a
photo of Cass No 5. The steam pipe comes out of the
boiler just below the steam dome and the exhaust pipe goes
into the side of the smoke box. Kenneth's design has the steam
pipe coming out the side of the steam dome and the exhaust going
into the bottom of the smoke box.
|Cass No 10: This photo shows both the steam and
exhaust pipes on Cass 10.
|This is the front of the exhaust pipe on Cass No 10; it goes
to the bottom of the smoke box.
|Flanges: Kenneth specified flanges on each end of the
1/2" steam pipe that runs from the steam dome to the steam
header. His drawings seemed to indicate that the 3/4"
exhaust pipe is to be soldered to the exhaust manifold at the engine end
and to the flange in the bottom of the smoke box at the front
end. The prototype had the exhaust pipe as a separate
piece with flanges that bolt to exhaust manifold at the rear and
the pipe from the smoke box at the front (previous photo). This seems to
be a more prudent arrangement --- easier to disassemble.
So, I made the four flanges shown on the right for the exhaust
system. The ID matches the OD of the 3/4" copper exhaust
pipe. A similar pair of flanges were made for the 1/2"
|The flanges were made from 1/8" CFS. They were sawed
from bar stock and then squared up on the mill. The four
were stacked and 1/16" holes drilled in the corners and roll
pins driven into the holes to keep the pieces aligned and
together. A 1/4" hole was then drilled in the center and
the pieces mounted in the lathe 4-jaw chuck and centered using the setup on the right ---- a length of 3/8"
rod was center drilled on one end and a short length turned to
1/4" on the other end. The rod was then inserted between
the tailstock and flanges and the chuck adjusted so that the rod was
centered. The flanges were then drilled and bored to the
correct ID. Later, the four attachment holes were drilled to
the correct size for 4-40 screws.
|Exhaust Pipe: The exhaust line between the engine exhaust manifold and the
exhaust inlet in the bottom of the smoke box was done first. The
flanges were silver soldered to the elbows as was the elbow to the big
flange at the bottom of the smoke box. I was afraid that
these joints would come apart if the 45
degree elbow was silver soldered into the 90 degree elbow connected
to the big
flange. Instead, that joint was soldered with 550 degree solder
(98.5% tin, 1.5% silver). This solder doesn't flow easily so the joint
was tinned with a a thin coat of solder in flux paste.
The solder then flowed easily and the temperature of the
combination seemed about the same as the 550 degree solder
The photo above shows the rest of the exhaust run. All the
joints were silver soldered except the one indicated. The pipe
was kept away from the boiler by 5/16". The lagging will be
1/4" so the pipe will be right next to the boiler jacket.
|Steam Pipe: Kenneth's design was followed for the steam
pipe. This photo shows the steam pipe just after the joints
were silver soldered (all joints were silver soldered). The
block at the end of the steam inlet header was made from 1.5"
diameter brass. There is a 1/8" MTP threaded hole in the
end for the pipe from the lubricator.
The photo below shows the finished pipes. Gaskets were fitted
to all flanged joins to insure a seal.
Next task is to layout the steam turret.