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Recreating LYN
Current Status of the Detail Design Work
updated 10/11/2015
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This is the current status page of the design and detailing blog for the recreation of the 1898 Baldwin narrow gauge locomotive known as LYN. The work on this project started at the begining of 2011 and to see the blog of the work during 2011 and 2012 please go to
page one. To follow the progress of the design from 2013 and 2014 onwards please go to page two. To see the latest work please go to page three

Go back to the latest entry on page 3



Summary of the Modelling and Detailing progress

I have finished modelling and detailing a significant part of the engine. I would guess that I am well over 95% of the way through the detail design. So far I have created more than a thousand 3D models that will be used to create drawings and probably close to 200 components that will be bought (screws, nuts, bolts, bearings & grease nipples etc.) The main assembly of the cad model now has around 6000 models assembled together.
Here is a summary of the work so far.

Boiler
The drawings for the boiler were not part of my original work program as it was expected that the boilermaker would be able to work from the comprehensive design layout created by Ian Gaylor. In the event the price quoted for the boiler included a significant price for the creation of the drawing(s) required for approval by the insurance company, the detail drawings for the components and the positioning of the stays. In order to make it possible to get the order placed I took on the detailing of the boiler as part of my work program and this is now complete. The boiler has been stress relieved and the tubes and stays are in place.
09/11/2013: The steam dome has been split to make assembly of the regulator easier. this should make future maintenance easier.
28/04/2014: The boiler is finished and ready to fit to the loco.

Superheater
The drawing set for the superheater is complete and the process of making it has started with the sourcing of the superheater tube return castings. I am expecting to have to make some adjustments to the drawings as the manufacture gets underway and the boilermaker gets to grips with welding the assembly. I have now redesigned the superheater to make the manufacturing easier. This is complete and issued for manufacture.
09/11/2013: welding of the superheater is now complete, the chambers have been stress relieved and are now being machined.
28/04/2014: The Superheater is finished and fitted to the boiler.

Smokebox
The main part of the smokebox is made as part of the boiler manufacture. All of the drawings have been completed but the cutouts and bolt holes for the fitting of the chimney and the mounting to the saddle can't be done until later in the assembly process when the assemblies are brought together.
28/04/2014: The smokebox is complete and welded to the boiler. The remaining holes will be added on assembly to the loco.

Cylinder
The drawings, CAD files and models for the cylinders are complete and issued for manufacture. Some of the parts have been made.

09/11/2013: Because of un-expectedly high manufacturing quotation I have been through the design and done some simplification. The drawings for this update are now issued.
28/04/2014: The cylinders are being made by Frosts of Norwich and are well advanced.
11/03/2015: the welding is complete and the cylinders have been stress relieved. Machining has started.
30/04/2015: Machining of the assemblies is finished and the liners are being produced.
26/06/2015: Machine of the main assembly is complete and the liners have been fitted. The last bits of machining and the pressure testing will be done soon.
14.10/2015: the Cylinders are fully assembled and the liners fitted. They have been sent to have the bores honed to final size and will then be complete.
The cylinders are finished and delivered to Keefs

Saddle
The drawings, CAD files and models for the saddle are complete and issued for manufacture. most of the parts are made and the welding of the main assembly is progressing.
09/11/2013: The manufacture is now complete except for a couple of small machining tasks.
28/04/2014: The saddle is finished and stored ready for assembly to the loco.

Regulator
All the components for the regulator have been modelled, detailed, checked, issued and manufactured. The only work remaining is to assembly them into the boiler and check the fit and function.
28/04/2014: The regulator is now fitted to the boiler and works well.

Chimney
The CAD models and the detail drawings are complete, checked and issued for manufacture.
28/04/2014: The main part of the chimney is finished but needs the injector exhaust pipework adding. This has been designed and modeled and will be completed later.

Blast stand
The CAD models and the detail drawings are complete, checked and issued for manufacture. We will need to revisit this as there has been a change in the requirement for this item.
17/02/2015: The blast stand is finished and ready to fit.

smokebox door
The CAD models and the detail drawings are complete, checked and issued for manufacture.
09/11/2013: The smokebox door is now manufactured.

Valve mechanism
The valve mechanism is modelled and detailed. The 2 conrods plus the shaft eccentrics and bearing details are drawn and, after incorporating the updates from the recent design review, will be awaiting checking.
09/11/2013: The valve drawings are now issued for manufacture.
17/02/2015: The valve components are curently being manufactures and I would guess that we are about 7/8 of the way through.

Motion
The motion parts are all modelled, detailed and awaiting checking.
09/11/2013: All drawings now issued for manufacture
17/02/2015: most of the motion is now manufactured.

Sand boxes
The sandbox parts are all modelled, detailed and awaiting checking.
17/02/2015: Under construction
01/04/2015: Sandboxes are finished except for the mounting brackets which will be welded on when fitted to the boiler.

Firearch
The firearch parts are all modelled, detailed and awaiting checking.

Firebox Door
The firebox door is Modelled and detailed. Before it is delivered for checking Ian and I need to have a design review and to allocate materials. This should happen in the next few weeks.
22/12/2013: review still pending.
28/04/2014: I am completing a redesign of this part and should issue drawings early next month.
17/02/2015: Under construction with Andy Bennett.
29/04/2015: The door is finished and delivered

Ashpan
The ashpan is modelled and detailed but needs a design review and some tweaking before I can release the drawings for checking.
22/12/2013: Review still pending.
17/02/2015: Review still pending - we will do this once the frame detailing is completed.
10/03/2015: We have had a quick review and I have a number of design simplifications to do. I plan to start these later this month
29/04/2015: Design review completed and the detailing about 50% completed.
30/10/2015: The detailing is completed and all drawings have been issued for checking.
30/11/2015: The ashpan drawings have been checked and issued for manufacture.

Cladding
The cladding is modelled and detailed but, before it is released for checking, I need to make sure it will fit on the boiler as made. There are bound to be a number of small dimensional changes to the boiler caused by the inevitable shrinkage during the welding process.

Cowcatcher
The Cowcatcher is modelled, detailed and issued, manufacture and all parts have been made and trial assembled by Alan Keef. All that remains to do is to rivet the parts together.
09/11/2013: all complete

Water tanks
The water tanks are modelled, detailed, checked and issued for manufacture.
28/04/2014: Water tank manufacture is well advanced and should be finished next month.
17/02/2015: completed.

The bunker
09/08/2014: The bunker is detailed checked and issued for manufacture.
28/04/2014: The bunker is finished and ready to fit.

The Axle Boxes
The axle boxes are designed and modelled and just awaiting final updates from the design review before I can finalise the detailing and pass for checking.
22/12/2013: the axle box drawings are finished and released for checking
28/04/2014: The axle boxes are being manufactured.
17/02/2015: the axle boxes are completed

The Axle and wheel assemblies
The Axle and wheel assemblies substantially complete and just need the mods from the design review adding and a final look over before I can finish the drawings and issue them for checking.

22/12/2013: the The Axle and wheel assembly drawings are finished and released for checking.
28/04/2014: The wheels have been finish machined and the rest of the axle components are well on with manufacture.
17/02/2015: the axle and wheel assemblied are all completed and ready to fit

The Frame
The Frame model is well advanced and the areas where it interfaces with completed assemblies are dimensionally accurate.
10/03/2015: The frame drawings are finished and issued for checking and quotation. There is a meeting soon with a potential manufacture and I am hoping for good news!
01/04/2015: All the plate work issued and the angle parts will follow very soon.
28/04/2015: All the drawings and the DXF files issued to Babcocks and they have started getting organised. 26/06/2015: Some fo the frame components have been delivered to Keefs. Assembly should start soon.
14/10/2015: The main side frames have been machined and are being assembled together.
30/11/2015: The frame assembly is complete and delivered to Keefs. Remaining holes will now be drilled

The Reverser
The design and modelling is complete and I am about to start the detail drawings.
09/11/2013: The redesign is now complete and I am starting the detailing of the components.
22/12/2013: the drawings are finished and are released for checking.
28/04/2014: The detail drawings are completed and await manufacture.
17/02/2015: most of the parts are made and awaiting assembly.

Front and Rear pony trucks
Front and Rear pony trucks are modelled in rough form only and will require substantial design and modelling before any detailing is undertaken. The rear pony truck will require a different mounting method to accommodate the deeper firebox and the design details will need significant design input.
28/04/2014: The front pony truck design is in hand. Ian is doing the calculations and I have started the modelling.
17/02/2015: Both pony trucks are designed and modeled. The detailing is started and should be finished soon, probably after the frame drawing are completed.
01/04/2015: detailing is finished and just awaits checking.
29/04/2015: I am about 50% through the updating of the drawings ready for issue. The axle assemblies are completed and issued. 26/06/2015: The front pony truck drawings are checked and issued for manufacture. The rear pony truck drawings are complete and issued for checking
14/10/2015: The front pony truck assembly is nearly finished and the rear pony truck has been started.
30/11/2015: The front pony truck is complete and the rear pony truck assembly is nearing completion.

The rear pony truck control assembly
26/06/2015: The rear pony truck control assembly is detailed and issued for checking.
14/10/2015: The assembly has had to be redesigned as the loads were found to be higher than the original design could manage. This has been done and the drawings are issued for checking.
30/10/2015: The drawings for this asembly are complete, checked and issued for manufacture

The brake stand
26/06/2015: The brake stand is modelled, detailed and issued for checking.
30/10/2015: All drawings are now checked and issued for manufacture.

The Steam dome cover
The Steam dome cover is roughed out only. Final modelling and detailing can be done once the cladding is complete.
17/02/2015: Drawing for the steam dome finished and sent to China for quotation.
26/06/2015: China unable to manufacture.
30/10/2015: drawings and CAD files issued to UK manufacturer.
30/11/2015: We are still having difficulty finding a manufacturer for these.

The Sand Domes
The sand domes are modelled only. Final modelling and detailing can be done once the cladding is complete.
17/02/2015: Drawing for the sand domes finished and sent to China for quotation.
26/06/2015: China unable to manufacture.
30/10/2015: drawings and CAD files issued to UK manufacturer.
30/11/2015: We are still having difficulty finding a manufacturer for these.

The Cylinder and Steam chest drain valves
10/11/2015: Modelled, detailed and issued for checking


Go back to Mike Nelsons Home Page

Useful links

762 Club Homepage
Lynton & Barnstaple Railway Homepage
Ian Gaylors's Homepage
Bennett Boilers Ltd Homepage
Alan Keef's Homepage

2010 Mike Nelson