With the majority of 3801's major components at contractors undergoing heavy repair, the overhaul team at Chullora have been busy attending to the many small details and fittings on the engine.

A continuing effort involves steam cleaning the myriad of boiler clothing and streamlining panels as well as the engine running boards, prior to repair and re-assembly.

3801's two mechanical lubricators and all the associated distributors, check valves and atomisers have been stripped down, cleaned and inspected. The engine has two lubricators, one supplying superheated cylinder oil to valves and cylinders, another supplies loco bearing oil to slidebars, axlebox wear liners and other moving parts. The lubricators are driven from the locomotive valve gear and operate automatically when the engine is moving.

Work is continuing on the locomotive's electrical system with manufacture of new steel wiring conduits.

During the first week of June new piston valve liners were installed by Goulburn based business Ainsworth Engineering Group (AEG). The liners (stock castings supplied by the NSWRTM) were machined by AEG and pressed into position in the locomotive frame.

The first of two cast iron cylinder liners was pressed into position on 9 June. This major job was performed by AEG using new castings sourced from Astral Alloys in Sydney. The traditional technique of pulling the liner into position with a pull-bolt and ratchet was successfully performed. The liner is pressed in with a moderate interference fit in the bore of the engine cylinder and secured in place with a pair of bronze locking plugs. After the liner was in position, the final bore was machined to the nominal size of 21-_ inches by Line Boring Services Australia. In addition, the front and rear faces of the cylinder were machined to provide a perfect mating face for the new cylinder covers.

A full new set of engine leaf and coil springs has been manufactured. New roller-bearing axle box liners have been pressed, fitted to the boxes and final machining performed at AEG.

Work has been progressing with rebuilding 3801's Westinghouse cross-compound air compressor for many months. Re-assembly of the compressor has now commenced after some specialised machining work by volunteers.

Rebuilding the interior of the engine's smokebox has been underway for the last a few months. The majority of internal bulkheads, baffles and platework that seals the smokebox air-tight suffer under the aggressive effects of heat, corrosion and erosion and require replacement.

The 3801 Overhaul project is led by Mechanical Engineer Craig Mackey and the mechanical work is supervised by RTM fitter Matthew Lee. Seventeen regular volunteers attend the 3801 Workshop on various days of the week to assist with the project. Currently two RailCorp Apprentice Fitters are assigned to the project.

All photographs © Craig Mackey

updated 5 August 2010