45015 Restoration Plan

"How are you planning to restore the loco?" A question frequently asked, and a very valid one considering the current state of the loco. Hopefully this page will provide some illumination of how we plan to go about this mammoth task:

S - Parts in Store
P - Some Parts in Store
C - Parts common to other BR Classes without modification
A - Parts could be adapted from other BR Classes (modified)
M - Parts not available from either C or A - would have to be manufactured
X - Parts available from various other sources incl. other (supportive) groups and relics sales such as Quorn, eBay, etc.

Note - Where more than one code is listed, then more than one option applies - there are several solutions to the missing part(s) depending on 'what turns up'

45015 Work Plan 2008 (Year 1) (Stage 1) Immediate Work and Preparation for Dismantling
Job No.	Description	Equipment Involved	Part Status						Remarks
Job No.	Description	Equipment Involved	S	P	C	A	M	X	Remarks
101	Board up access to all cab doors (due to safety reasons)	All cab doorways							Until Further Notice
102	Reinstate No.1 wheelset	Replacement springs; hangers; coil springs	S						Assess No. 1 wheelset axle bearings (SKF) for service condition
103	Oil up all fastenings at least 3 times with thin oil/WD40	All fastenings							Except where very heavily corroded - to be cut/burnt off after noting fastening details
104	Make notes of arrangement of all equipment, e.g. roof lining, pipework, etc., to completion	All equipment where required							To include photographic records
105	Label up parts in conjunction with 4) to completion	All equipment where required							Labels to be serviceable
106	Installation of workshop and stores facility with shelving/racking. Acquisition of tools for workshop	Purchase of Mk1 vehicle + flat wagon (or container)							Mk1 BG acquired (2003) but stored off site OOU. Flat wagon or container now optional. Permission may not be given for BG onsite in addition to locomotive (Note 1)
45015 Work Plan (Year 1/2) (Stage 2) Dismantling
Job No.	Description	Equipment Involved	Part Status						Remarks
Job No.	Description	Equipment Involved	S	P	C	A	M	X	Remarks
201	Remove all large items of equipment from locomotive and relocate to 1) stores or 2) flat wagon and sheet over or (3) storage facilities away from the present site	Engine room roof panel Silencer panel Engine/generator unit Boiler (in arrangement with asbestos removal) Brake frame Vacuum exhauster Electrical control cubicle Radiator fan grille Radiator fan assembly/tunnel Fuel tanks (2) Water tanks (2) Main air reservoirs (6) Battery boxes (2) Body side grilles (2) + (2)
45015 Work Plan (Year 2/3) (Stage 3) Restoration - External
Job No.	Description	Equipment Involved	Part Status						Remarks
Job No.	Description	Equipment Involved	S	P	C	A	M	X	Remarks
301	Restoration of body shell including underside. Removal of cab structures. Eliminate all corrosion. New plate where required	Cab structure Nose end assembly Nose end floor Bodyside and cantrail areas Boiler room floor area							Repaint in BR blue - transfers; BR >>
302	Restoration of bogies (outside only)	Remove all rust and corrosion. Paint in black
303	Manufacture of missing or corroded bodyshell items	Doors Handrails Boiler room roof panel Gutter sections Silencer panel (if too corroded) Bodyside (filter on 46's) cover panels Nose end filters					M M M M M M M		Or repair existing item
304	Sourcing of missing bodyshell items	Various solebar fittings - cocks and drain taps Wiper arms, blades			C C
305	Recondition existing bodyshell items	Engine room roof panel Radiator fan grille Main air reservoirs (6) Battery boxes (2) Bodyside grilles (2) + (2) Wiper motors		P					All items of equipment to be bench tested for operation/checked for calibration before installation
306	Manufacture of missing bogie items	Sand valves Sand pipes *					M M		All items of equipment to be bench tested for operation/checked for calibration before installation
307	Sourcing of missing bogie items	Sandboxes Sand pipe brackets Steps						X X X
308	Recondition existing bogie items	Sandboxes Sand pipe brackets Steps Speedo drive Distance counter	S S						All items of equipment to be bench tested for operation/checked for calibration before installation
309	Fitting parts from Jobs 303 - 305 to completion (Group A - External Completion Components)	As Listed
310	Fitting parts from Jobs 306 - 308 to bogies to completion	As Listed
45015 Work Plan (Year 4/5) (Stage 4) Restoration - Internal
Job No.	Description	Equipment Involved	Part Status						Remarks
Job No.	Description	Equipment Involved	S	P	C	A	M	X	Remarks
401	Manufacture/Sourcing of missing parts (Group B - Other Components)	Automatic Voltage Regulator Traction motor blower motors/fan assemblies Battery charging/plug equipment board Engine room/boiler room internal door				A A	M M M		All items of equipment to be bench tested for operation/checked for calibration before installation (Note 2)
402	Recondition of existing parts (Group B - Other Components)	Electrical control cubicle Battery Isolation Switch Brake frame Engine/generator Vacuum exhauster Radiator fan assembly/tunnel (with radiator elements) Combined pump set (motor - rewind) Convertor set Fuel tanks (2) Water tanks (2)	S S S S	P P	C C	A A	M	X	All items of equipment to be bench tested for operation/checked for calibration before installation Serviceable Class 47 power unit to be obtained (Note 3)
403	Fit parts from Job 401 & 402 to locomotive	As Listed
404	Manufacture of missing cab fittings	Nose end access door Secondman's steam heat monitor panel Traction motor access door Engine room access doors					M M M M		All items of equipment to be bench tested for operation/checked for calibration before installation
405	Sourcing of missing cab fittings	Secondman's steam heat monitor panel pressure gauge Driver's desk gauges Cooker units Tail lamp brackets	S					X X X	All items of equipment to be bench tested for operation/checked for calibration before installation
406	Recondition existing cab fittings	Power controller assembly Drivers loco air brake valve Drivers train brake valve AWS fittings Seats Heaters Bulkhead fittings (including terminal boxes)	S S S S		C			X X	All items of equipment to be bench tested for operation/checked for calibration before installation
407	Installation of all interior cab structure	Floor; desk; cooker pedestal; roof lining; cab insulation							All items of equipment to be bench tested for operation/checked for calibration before installation
408	Fit parts from Jobs 404 - 406 to locomotive	As Listed
409	Wiring up locomotive to wiring plan	All electrical equipment							All circuits and equipment to be tested on completion of wiring
45015 Work Plan (Year 5/6) (Stage 5) Restoration - Bogies
Job No.	Description	Equipment Involved	Part Status						Remarks
Job No.	Description	Equipment Involved	S	P	C	A	M	X	Remarks
501	Install temporary accommodation bogies under locomotive	2 bogies							Not acquired - use steel frame instead or pile of sleepers?!
502	Remove items not required for overhaul	Steps; sandboxes and valves; speedo assembly; distance counter; buffer beam fittings
503	Overhaul of Bogies 1/339 & 1/340 to 'Network Haulage Standard'	Bogies; axleboxes; traction motors; brake cylinders; buffers; pipework
504	Repair of damaged No.1 traction motor gearwheel assembly	Motor shaft Motor pinion Axle gearwheel Gear casings Pinion retaining ring					M M	X X X X	Require repair (build up damaged surface by weld, machine)
505	Overhaul of traction motors	All traction motors
506	Manufacture of missing brushboxes and covers; terminal box covers and links						M	X
507	Fit items from Job 506 to motors
508	Recondition all other fittings - buffer beam hoses, couplings
509	Install overhauled bogies
510	Fit items from Job 508 to bogies
511	Reconnect bogies to all locomotive systems	Brake; steam heat; vacuum; sanding systems; handbrake; traction motor cables
45015 Work Plan (Year 7) (Stage 6) Equipment Testing
Job No.	Description	Equipment Involved	Part Status						Remarks
Job No.	Description	Equipment Involved	S	P	C	A	M	X	Remarks
601	Installation of batteries	96 Cells
602	Testing of equipment and systems on locomotive	All electrical equipment; oil, fuel and water circuits; brake systems
603	Testing of power unit on locomotive	Power unit (1 hour test under observation)
604	Correction of any faults found followed by further test
45015 Work Plan (Year 8>) (Stage 7) Miscellaneous Items
Job No.	Description	Equipment Involved	Part Status						Remarks
Job No.	Description	Equipment Involved	S	P	C	A	M	X	Remarks
701	CO2 system and fire detection equipment	CO2 pipework; gas bottles; fire detectors	S
702	CWA apparatus	Stone Vapor steam generator (OK 4625)

NOTES

1) BG would (if it is to be used for intended purpose) require to be fitted out as a properly laid out workshop and store. Otherwise to be sold
2) Board could be constructed using parts under C above
3) Most of the Allen West relays required (same spec. number for a Class 45) are in store but some relays and most electrical (other) items required such as busbars and terminals, cable ducting etc.