April 2021 saw the frames lifted from its wheels and the pony truck was stripped for inspection.
It was at this point we found the frames were bowing and in need of straightening. To do this we warmed the top of the frames above each wheel set. Both sides were done in tandem and once cherry red the pedestal binders were refitted and allowed to cool. Once completed the frames were painted. The great thing of working with American locomotives is that every single sort of repair you could ever imagine is codified to the exact letter of what you need to do – straightening the frames was no different.
In May the boiler continued to receive the new mud hole doors. The foundation ring rivets along each side were replaced. The flexible stay caps were also finished in this period. Towards the end of the month the boiler was rotated 180 degrees to allow ease of access on the super heater header flange and allow easier access for welding over the firebox. While this way around the boiler received 2 new BR Standard gauge frames on the right-hand side. Then we removed the old as fitted reflex gauge stabbings. When the engine arrived it was right hand drive but the decision was made to convert it to left hand drive for ease of operation. This included moving the regulator, blower, and reverser.
Cheddleton Carriage and Wagon department is very lucky to have a Master Pattern Maker volunteering with them. This was made use of, as a new center casting was required for the firebox grate. The pattern was made in house and 5197 has been running with this casting ever since. A second was cast for 3278.
All the wheels had their quartering checked and a fault was found on one of the axle journals which couldn’t be ignored. The wheel set was sent for machining off site (Riley and Sons). As the journal was now smaller the axle boxes for this wheelset needed to be re-metaled. Upon closer inspection all the axle boxes ended up being re-metaled.
31st August saw the first steam test of the boiler while it remained on the ground in Cheddleton yard.
Over the course of August and September the final touches were made to the boiler. October saw the staff turn away from 3278 as the Christmas period fast approached. 6046 stayed at Cheddleton operating Churnet Valley Railway’s first Polar Express TM Train ride while 5197 went to Cholsey and Wallingford Railway. Both were successful seasons for the engines with neither missing a day of operation or delaying a train.
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