toxx
|
New design for a D455H'llo, folks! The Wilesco D455 is about as typical as they come (quote Rog; the man's right  !), so I decided to give mine a new look with a home-made fire box, a pressure gauge (Manometer in German), and a new whistle, since the Wilesco turn-lever whistles are Scheisse. I mail-ordered the parts I needed from Wilesco in Lüdenscheid and went to work. I made a new baseplate out of plywood covered with brass plate, tossed the original and the fire box. Then I bought some aluminum profile stuff and started cutting, filing, sanding and bolting together a frame for my new fire box. It will be larger, and tadaaah! will be encased with genuine miniature bricks. These are from the spanish company "Teifoc". They are real, genuine bricks, just en mini. God bless the Spanish. I'll keep you guys posted of how this project turns out. Here's a pic of the status quo.
Greetz and cheers from Vienna says
Tom 
[img] [/img]
|
Mister Occlusion
|
That's going to be a real eyecatcher when it's done. Massive structure there.
I ordered an adapter and D22 whistle for my 455, just because those little ones are so leaky and squeaky.
|
SillyBilly
|
Can hardly recognise it's the same engine. Well done, very imaginative.
|
johnreid
|
This looks like the making of a very nice engine.
|
toxx
|
... thank you, friends! I'll post some more pix when I start the first row or two of the little bricks. I'm also gonna clad the boiler with wood strips and fasten them with copper or brass straps.
Cheers, Tom
|
Graham-Jilly
|
should look great when finnished
|
Mamodman123
|
Looking great so far Tom! can't wait to see it finished
|
MTA
|
Looks great so far. One thing Toxx, are you going to make the firebox bigger? A fair bit of the burner is outside it, therefore all the heat from the burner will not be transferred to the boiler therefore wasting fuel... I suggest making a cone shape for the firebox that will extend round the entire burner then meet at the edge of the boiler, so it funnels the heat to the boiler 
Not picking holes or anything like that, just saying 
|
toxx
|
| MTA wrote: | | Looks great so far. One thing Toxx, are you going to make the firebox bigger? A fair bit of the burner is outside it ... |
Yes, that's exactly what I've planned. What you see right now is the Wilesco configuration: The burner tray is a wee bit too long for the narrow space of the firebox. I was thinking - just like you suggested - of putting a brass cone on it. Also, I'm gonna "cluster" the Esbit closer together in the tray, or maybe use a meths wick to channel the flame better.
But it's a long way before I get there!
Greetz, Tom
|
MTA
|
| toxx wrote: | | MTA wrote: | | Looks great so far. One thing Toxx, are you going to make the firebox bigger? A fair bit of the burner is outside it ... |
Yes, that's exactly what I've planned. What you see right now is the Wilesco configuration: The burner tray is a wee bit too long for the narrow space of the firebox. I was thinking - just like you suggested - of putting a brass cone on it. Also, I'm gonna "cluster" the Esbit closer together in the tray, or maybe use a meths wick to channel the flame better.
But it's a long way before I get there!
Greetz, Tom |
Great minds think alike  I can't wait to see this one finished now 
|
flywheel61
|
Wow, that a lot different form the original, good one Tom.
Cheers
Chris
|
rangerssteamtoys
|
Cool, your becoming an engine modifier. Cant wait till the genuine brick is on there.
|
Steve_S
|
That's a great project. I'll be very interested to see the outcome! 
|
IndianaRog
|
Tom, you are doing some cool stuff there...won't be anything tinny about that model when you are done with it...rising like a skyscraper!! Bricks will be a really nice touch.
cheers,
Rog
|
Cranko
|
Lookin Good Tom, keep those pictures coming
|
steamyman
|
very creative, Tom.
|
Wallace
|
Oooh, that's coming along nicely Toxx
|
toxx
|
Re: New design for a D455H'llo and good evening, my friends! First of all I want to say thanks to all of you. Your kind words are an encouragement! It's real nice to have friends in our hobby scattered all over the world. Good to be with you lot! 
Here's the structure as of this afternoon. The bricks are just fine and hard as rock. I had to split a few to make them fit the aluminum structure. I used "Moltofill" as cement - I'll have to scrape off residue on the bricks. It don't come off easily! This is pure "learning by doing". The machine is shrouded to protect her from brick dust - and a lot of that there is!
Meine Freunde, liebe Grüsse aus Wien
Says your old Tom
|
MTA
|
How are you going to get the burner in? 
|
johnreid
|
I think this is going to look like a museum piece. I bet you have to wipe the Moltofil off after each brick is placed.
|
oldstuff
|
Great project and coming together nicely, toxx.
Can't wait to see it all done...I have to be patient, though!
|
toxx
|
H'llo, friends! Yep - that's what I'm gonna do: Keep a cloth handy and wipe. Learning by doing! Once the Molto is dry it's like cement. The burner tray (I'm using the original Wilesco piece) fits nicely inside - but you're right to be weary! It's a tight fit. Yet - it can get in and out quite easily. The plastic handle will be entirely emerged into the firebox (sans heat), the opening will get a hinged "fire door".
Cheers, says Tom
|
Graham-Jilly
|
looks good Toxx should be a stunner when its finnished
|
johnreid
|
If the brick do not clean up enough, use a wire wheel attachment on a Dremel, and just dont get carried away. I think this one is going to be a piece of art.
|
IndianaRog
|
Tom, when you said you would be using little bricks...you were not kidding...those are REAL little bricks. I was thinking doll house sort, but these you could build a house with (albeit slowly).
Nice to see it coming together...we all learn by watching.
Rog
|
Sandman
|
This is going to be a classic.
Most impressed.
|
Mister Occlusion
|
Cool.
I bet you could get the residue off with a little sand paper on a block. It'll wear the bricks down a bit, but then they ought be a bit smooth anyway for the scale effect.
|
Wallace
|
I'm really looking forward to the end result.
|
tmuir
|
Just found this thread, this is going to be one unique engine and I'm now hooked to see the finished project.
Its certainly going to be one heavy engine once finished and no heat will escape out the side of that firebox.
Keep us all informed on your progress.
|
Cranko
|
Those little bricks certainly add to it Tom , Well done
|
toxx
|
New D455 project pix!H'llo, friends! Tom (oi, tthat's me! ) the Brick Layer has laid the last brick to the D455's new structure. I also added a copper fire house door, with darling little brass hinges (door turned out a wee bit crooked, oh well. I can live with that). Next, I'm gonna top the bricks with kinda adobe-style brick shindles from the same company, Teifoc of Spain. The boiler will be clad with wood secured with brass straps. Hope you like the pix! The little loco on the edge of the picture is a home-made shunter, a German 'Köf', made of wood and other stuff I had at home.
Cheers, me good lads!
Says your old Tom
|
MooseMan
|
Tom, that rocks! My old D45 is untouchable (my first ever engine, 10th birthday present) - but I may have to start looking out for another one. Wilesco should hire you!
|
tmuir
|
Wow, that's turning into a serious peace of kit.
I'm not that familiar with Wilescos, any chance of you posting a picture of the engine in its original state so I can compare?
|
Chris
|
Looks great! Did you use regular mortar, or some kind of pva glue mix to stick the bricks together?
|
johnreid
|
Wow, good job. I like what I see.
|
toxx
|
| tmuir wrote: | Wow, that's turning into a serious peace of kit.
I'm not that familiar with Wilescos, any chance of you posting a picture of the engine in its original state so I can compare? |
H'llo, tmuir! I found this pix on ebay of an original D455 and simply stole it. One of the problems I had with the D455 is (though a darling little chuffer it is!), when running with high rpm's, the machine starts to "dance" due to its light structural mass, i.e., the base plate is too small&light.
Cheers from Austria to Australia!
Says Tom
|
toxx
|
| Chris wrote: | | Looks great! Did you use regular mortar, or some kind of pva glue mix to stick the bricks together? |
H'llo, Chris! No, basically, I used "Moltofill für Aussen", a cement like stuff you buy at a home-improvemant kind of store (I'm a devote follower of Tim Tailor, aka Tim Allen). The stuff hardens like cement, and is not water solable. Where the bricks meet the aluminum structure, they are also glued to it with epoxy resin, same as the bottoms of the lowest bricks. The Molto will not hold to the brass base plate, so the lower bricks are slathed with epoxy.
Kind greetz, says Tom
|
tmuir
|
Thanks Tom, that's a big improvement.
I have that problem with a number of my engines wanting to 'run away' under full steam.
I used to use a type of G clamp that has a rubber foot on it to stop my engines running away until I discovered all I needed to do was put a towel under it. It was the smooth surface of the table giving me the problems.
Sometimes the easiest solutions are just overlooked because they are too simple.
But I do love what you have done there, making it all look much more robust and will probably work better as the heat will no longer be escaping out the sides of the firebox.
On the original firebox it has air holes in it, have you put any in your brick firebox?
|
SillyBilly
|
Want an improvment, I love it mate! You've done a lovely job laying those bricks.
|
MooseMan
|
I've toyed with the idea of mounting a great big magnet underneath my worksurface, but it's also known as the kitchen table, so it might have interesting side effects on cutlery.
|
Mister Occlusion
|
That's looking first rate. The lagging of the boiler will really finish it off.
The gauge/SV device that you have. Is that the straight D21 part or did you have to get an adapter for it?
I just mounted a D22-style whistle on my 455, with an M5/M6 (or is that M6/M5?) adapter. The gauge might be a nice feature as well for me...
|
James
|
That's awsome!!!
I Want one!
|
toxx
|
| Mister Occlusion wrote: | That's looking first rate. The lagging of the boiler will really finish it off.
The gauge/SV device that you have. Is that the straight D21 part or did you have to get an adapter for it?
I just mounted a D22-style whistle on my 455, with an M5/M6 (or is that M6/M5?) adapter. The gauge might be a nice feature as well for me... |
Yo, Mr. O! No, the D21 part with built-in security valve fits without an adapter. I also got the pull-chain style whistle to replace the turn-lever whistle (I just hate them!), but that needed the M6/M5 adapter.
Kind greetz from Vienna!
Says Tom
|
toxx
|
Yo, me dear friends! Thank you, I'm glad you like the pictures. I'll post some more when I get some work done on the boiler!
Cheers, mates!
|
Cranko
|
Hi Tom, I'm concerned you wont get sufficient air to allow combustion as tony pointed out, may be a good time to try it 
|
Mamodman123
|
100 million times better now
|
toxx
|
| tmuir wrote: |
... on the original firebox it has air holes in it, have you put any in your brick firebox? |
Hi, tmuir! Yes, I put in some air holes. If you look closely at the 2nd lowest row of bricks, you can see the openings on both sides. They're pieces of square aluminum pipe. I hope enough air will get in this way. If not, I can always leave the fire box door open.
Cheers, mate!
Says Tom
|
Roly Williams
|
| Mamodman123 wrote: | | 100 million times better now |
I've told you a trillion times - don't exagerate
|
Graham-Jilly
|
looks great well done
|
mc_mc
|
That turns an ordinary looking engine into something special. And it certainly won't be dancing round the table now.
Nice job!
|
syrtismajor
|
That is an awesome modification! Tempted to try something like that myself,,
|
Wallace
|
That's great Tom, well done.
Makes it look so much better
|
toxx
|
H'llo, me friends!
Here are two more pix of my refurbished D455. I've completed the brick structure - looks like a tiny crematorium. Also planked the boiler with mahogony-dyed wood - looks kinda reddish. Secured with brass straps.
Put ship's planks on the fire box roof. Now there are only little jobs to to, like adding some more detail, a transmission and a lovely old Wilesco generator, the old metal kind. Hope y'all like the pix!
Cheers, mates
Tom
|
johnreid
|
WOW, that is fantastic, real good job there.
|
tmuir
|
Wow, that looks like a completely different engine.
I like it a lot.
So when is the grand steaming going to happen?
|
Mister Occlusion
|
That lagging just finishes it off so nicely. Fantastic
I've been thinking of lagging my old brass boiler Jensen 25, but have not figured out how to go about it yet...
|
toxx
|
| tmuir wrote: | Wow, that looks like a completely different engine.
I like it a lot.
So when is the grand steaming going to happen? |
... glad you like her! Tomorrow, I'm gonna give her a twirl. No, that sounds too hm, hm. Tomorrow, I'm gonna light her fire. Well, you know what I mean!
Cheers, mates!
Tom
|
Graham-Jilly
|
mate that is awsome
when are you going into production
|
tmuir
|
| toxx wrote: | Tomorrow, I'm gonna give her a twirl. No, that sounds too hm, hm. Tomorrow, I'm gonna light her fire. Well, you know what I mean!
Cheers, mates!
Tom |
LOL,
What ever is your fancy Tom.
Either way its going to end up steamy.
|
MooseMan
|
WOW!!
If I saw that in a shop I'd buy it!
|
James
|
WOW!!
What a transformation
Brilliant! I love it!
|
SillyBilly
|
Truly Awsome.
|
Roly Williams
|
It's looking great, but I agree that you may need to remove a few more bricks for air - something like 2 or 3 whole bricks on each side.
I like the mahogony finish on the lagging. The whole thing is a great improvement on the original.
|
toxx
|
| Roly Williams wrote: | It's looking great, but I agree that you may need to remove a few more bricks for air - something like 2 or 3 whole bricks on each side.
I like the mahogony finish on the lagging. The whole thing is a great improvement on the original. |
... I've got 2 air holes on both sides, plus holes on top. Also, there's a crack where the bricks meet the the roof. Ihope that's enough! If not, I'll have to leave the fire box door open or even drill some more holes. We'll see tomorrow!
Greetz, Tom
|
Andy
|
it lookin amazing good work
|
Cranko
|
A complete transformation Tom Well done
|
toxx
|
| Cranko wrote: | | A complete transformation Tom Well done |
Thank you, Cranko! What do you think of the air flow? Will my 2 openings be enough? I'd hate to have to drill new holes ... should the air holes prove insufficient, would leaving the fire box door be enough?
Greetz, Tom 
|
steamyjim
|
What do you mean by transmission-a lineshaft mounted on the engine??
I didnt no Wilesco did metal dynamos
|
toxx
|
| steamyjim wrote: | What do you mean by transmission-a lineshaft mounted on the engine??
I didnt no Wilesco did metal dynamos |
Hi, Jim! Lineshaft - hm, I'm unsure of the correct English word . In German, it's called "Transmission", a gadget to which you hook up the other stuff to the engine, dynamo, saw, drill, etc., usually using flexible spring-like belts.
Wilesco did make metal dynamos, but switched to plastic in the 80ies. I got mine, an unused beauty in its original box, of ebay for only 18 Euros.
Greetz, Tom
|
steamyjim
|
Yes a think lineshaft is the english word
I never new they did metal ones Learn something every day
|
toxx
|
| steamyjim wrote: | Yes a think lineshaft is the english word
I never new they did metal ones Learn something every day |
H'llo, Jim! Here's a pix of the metal beauty:
Greetz and cheers, mate!
|
steamyjim
|
OOOOOH very nice.
|
TRAPPERKEEPER
|
Nice Tom!!! That is one great looking engine, the bricks are so nice and the wood is a grand touch. Excellent work
|
toxx
|
| TRAPPERKEEPER wrote: | | Nice Tom!!! That is one great looking engine, the bricks are so nice and the wood is a grand touch. Excellent work |
Thank you, Trap! I'm kinda nervous over tomorrow's first firing. I hope the air ducts are sufficient for enough oxygen! I'd hate to have to drill new holes in those neat little bricks ...
Kind greetz, says
Tom
|
Andy
|
if you don't mind me asking how much was it and where did you get it from
|
toxx
|
| andypt677 wrote: | | if you don't mind me asking how much was it and where did you get it from |
... what, Andy? The bricks? The engine? The dynamo?
|
Andy
|
soz the dynamo
|
toxx
|
| andypt677 wrote: | | soz the dynamo |
Hi, Andy! I got it off ebay. Careful, the old, metal ones have the same Wilesco production number M66 as the current ones, which are either out of red or black plastic. The older metal ones have this sickly greenish tone. I got mine for only 18 Euros ...
Cheers, mate!
Says Tom
|
Andy
|
thank you just thoughy it would look gd on my wilesco convertion
|
toxx
|
H'llo, me lads and I hope a few lasses! Fired me wee new lady's fire twice today (after all, I am an adult! Tom, cut the crap ) and she went off like a charm. I mean, man, real sexy, man (here he goes again).
No, really: I was kinda worried about the tiny air holes, and whether they would provide enough oxygen. But the Esbit burned with a nice blue flame, no residue left in the tray (which would have been a bad omen). The first trial run had some steam leaking at the pressure gauge. Remedied that with a new washer. Also, I only used 3 Esbit bricks, and had the boiler 3/4s full. The pressure only went up to 1/2 bar. For the second run, I emptied the boiler to 1/2 full, and used 4 Esbit bricks (as much as I love flame and water, electricity would be a blessing for this large boiler and tiny burner). Pressure went up slightly over 1 bar, and the machine went off like a rocket. Even though she weighs half a ton now, the vibrations are still pretty heavy, so I'm gonna put some rubber "feat" on the base plate. Otherwise: The bricks hardly generate heat, I can touch almost everything without risking burns. Only the aluminum parts of the frame, which show on the fire box top, get extremely hot. She also - as due to the nature of the D455 - spits steam and crud all over the place, including her nicely wood-clad ass. I'm gonna have to think of a home-made condensator, or whatever they're called ...
Kind greetz and cheers, me friends,
Says Tom
|
tmuir
|
Glad it all ran well Tom.
I hope you can do a video for us.
You certainly have an original Wilesco variation now.
|
toxx
|
| tmuir wrote: | Glad it all ran well Tom.
I hope you can do a video for us.
You certainly have an original Wilesco variation now. |
... thanks! I'll try to do a video - I don't have a camera, myself.
Greetz, Tom
|
IndianaRog
|
Congrats Tom...got a chuckle out of reading your review of your new "Lady".
Pictures are a must...your public awaits!!!
Rog
|
toxx
|
| IndianaRog wrote: | Congrats Tom...got a chuckle out of reading your review of your new "Lady".
Pictures are a must...your public awaits!!!
Rog |
... thanks, Rog!
Greetz, Tom
|
Cranko
|
Glad your new lady is a real good looker and a good runner
|
Andy
|
glad to here that she work tom
|
toxx
|
| andypt677 wrote: | | glad to here that she work tom |
... thanks, Andy! I gotta make some kind of condensator, since she spits exhaust all over the table.
Greetz, Tom
|
rangerssteamtoys
|
I am likeing the way you project is turning out. If it were me I would route the steam to the chimney, the steam will create a bit of a up draft if you point the pipe up so making your fire even better for that boiler.
Hope this helps.
|
Roly Williams
|
| rangerssteamtoys wrote: | I am likeing the way you project is turning out. If it were me I would route the steam to the chimney, the steam will create a bit of a up draft if you point the pipe up so making your fire even better for that boiler.
Hope this helps. |
Not a good idea if it "spits steam and crud all over the place". Solid fuel tablets get nasty if they get wet, and even a meths burner wouldn't be too happy about it. 
|
rangerssteamtoys
|
| Roly Williams wrote: | | rangerssteamtoys wrote: | I am likeing the way you project is turning out. If it were me I would route the steam to the chimney, the steam will create a bit of a up draft if you point the pipe up so making your fire even better for that boiler.
Hope this helps. |
Not a good idea if it "spits steam and crud all over the place". Solid fuel tablets get nasty if they get wet, and even a meths burner wouldn't be too happy about it. |
I thought about that and figured that you could put a metal splatter gaurd type thing that will keep the water and oil from reaching th bottom and instead just burn off.
|
Roly Williams
|
| rangerssteamtoys wrote: | | Roly Williams wrote: | | rangerssteamtoys wrote: | I am likeing the way you project is turning out. If it were me I would route the steam to the chimney, the steam will create a bit of a up draft if you point the pipe up so making your fire even better for that boiler.
Hope this helps. |
Not a good idea if it "spits steam and crud all over the place". Solid fuel tablets get nasty if they get wet, and even a meths burner wouldn't be too happy about it. |
I thought about that and figured that you could put a metal splatter gaurd type thing that will keep the water and oil from reaching th bottom and instead just burn off. |
That would work, provided it didn't restrict the flow.
|
rangerssteamtoys
|
| Roly Williams wrote: |
That would work, provided it didn't restrict the flow. |
Well yes, I think it would even out though. The steam exhaust trying to pull up air while the splatter gaurd restricts it a bit.
|
toxx
|
| rangerssteamtoys wrote: | | Roly Williams wrote: |
That would work, provided it didn't restrict the flow. |
Well yes, I think it would even out though. The steam exhaust trying to pull up air while the splatter gaurd restricts it a bit. |
... good idea, lads, thanks! I was thinking of seperating the stuff in a condesator of some sort and leading the steam sans oil and water to the chimney. Hm, I gotta give this some thinking.
Greetz, Tom
|
Wallace
|
| rangerssteamtoys wrote: | I am likeing the way you project is turning out. If it were me I would route the steam to the chimney, the steam will create a bit of a up draft if you point the pipe up so making your fire even better for that boiler.
Hope this helps. |
I think that's a good idea ranger, and it does work.
My Brothers homemade engine has a chimney off the firebox, all open (picture a #75 but with the firebox open to the chimney).
He vents the exhaust to the chimney, and it creates a slight updraft and the steam/oil hitting the hot chimney seems to make the chimney exhaust look more effective.
His releif valve can also be manually operated (it's a valve off a hot water system), and when operating that, at full pressure, the updraft is VERY noticeable. Flame size increases.
|
syrtismajor
|
toxx,
That is a wonderful piece of modification! I love the bricks!
That would have been the engine I would have bought if I weren't swayed by the Jensen 75, and what you've done to it is amazing. You must make a video of it running!
|
bessytractor
|
its excellent. i especially like the ships planks, an excellent detail
|
toxx
|
... thank you! I'm going to add an condensator and two dynamos to power some neat little brass lamps. Wish I could show a video of her running, but I don't have a camera to do so.
Greetz, Tom
|
