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There are now many regulations concerning the manufacture of loco boilers. The 5 boiler inspectors (Gordon Bullard, Stu Davidson, Eddie Gibbons,
Brian Nicholls & Ian Spencer) are happy to advise & support you through your boiler build. It is far better to discuss your project before committing
time and money rather than finding your boiler does not meet current standards after finishing it. The boiler inspectors will also issue an intermediate report part way through the build so that you have a record of what is inside the boiler before soldering the inside & outside parts together.

  

There are 2 main suppliers of silver solder, Johnson Matthey and CUP Alloys. Their web sites have some useful information.
Please follow the links below.

 

Johnson Matthey:    http://www.jm-metaljoining.com/

CUP Alloys:               http://www.cupalloys.co.uk/

 

Polly Model Engineering offer advice on basic silver soldering:

  

http://www.pollymodelengineering.co.uk/global/technical-notes/basic-silver-soldering.asp

 

Mainstream Steam offer silver soldering for beginners:

 

http://www.mainsteam.co.uk/articles/silversoldering.htm

 

A video showing silver soldering a bush in a 16mm boiler may be of interest:

  

http://www.youtube.com/watch?v=WEtUJQuK-z8

 

 

If you know of any useful links please send them to the secretary to add to this list & help your fellow modellers.

 

A sequence of photographs & commentry illustrate the completion of 2 'Compbyne' boilers on Stu's boiler page (link above). Work has stopped
for a while on the project below, but will be completed in the not too distant future!

Stage 1 - working out the most economical way to cut the sheet copper and then rough cutting the pieces with an angle grinder fitted with a 1mm thick 
metal cutting disc then using a bandsaw to cut the outline.

 

     

 

The plates are then heated to red hot to soften the metal prior to bending round the flanging formers.

           

Rather than hammering the copper directly, a piece of nylon bar can stop hammer marks appearing.

 

       

The plates will work harden and need reheating to finalise the flanging process.

 

Once the plate is flanged it is secured in the milling machine and excess material is removed.

         

 

 

A set of flanged plates finished in the same way.

 

The embryo barrel for this 5" boiler  needs a lot of heat to soften the extensive area before the shaping process starts.

         

 

         

 

Once cooled the formation of the tapered barrel can start. The shape was cut using a paper template generated using geometric triangulation. 
The first picture shows the resourceful set up necessary to manipulate the flat shape into a tapered cone.
The following pictures show the gradual process initially pushing the sheet then using a soft hammer & block of wood to prevent bruising &
ensure uniform bending over the full length.

          

 

         

 

         

 

         

 

          

 

         

 

         

 

The final pull together of the seam can be achieved using Jubilee clips.

 

         

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