Bending pipes.

6023's steel pipework had rusted through at Barry, and a copy set was made using patterns from 6000 King George V when in the old GWR museum at Swindon. Despite being copies, dozens of extra bends and cuts had to be made, as GWR pipes were vitually handmade - this was not mass production. Here a Propane/Oxygen torch is being used to heat a pipe before adjustment.

Richard heating a steam pipe.

The pipe wall is thick enough to withstand 250psi steam pressure. To bend or realign the pipe the walls have to be heated until they glow red, then a careful bend is put in while the pipe is soft.

Three Cone Ejector

The black device on the right side of the firebox is the 3 cone ejector - this has a steam powered jet used to create a rapid vacuum in order to release the brakes on the locomotive and any vacuum-brake fitted train it is pulling. Note the pen marks for planning the next steam pipe.

Cladding and nameplate.

Contrast this photograph with the August 2002 one at the same spot. An exceptionally difficult piece of cladding was the curved 'Elephant's Ear' between the tubular part of the boiler and the firebox.

Right side view.

Contrast this was the same view from August 2002.

Grinding part of a steam pipe.

More grinding.

All of the 6023 team get introduced to new skills, and are trained to make the best use of them with the right safety equipment.

Martin grinds another pipe in the vice.

Freshly cut plates of steel.

For cutting steel we generally use a large petrol disc-cutter.

Well, this is December!

The left hand connecting rod needed the whole team to lift it.

Timber!

The left hand crosshead being 'murdered' to the full length of its forward travel. Careful filing of its bearing surfaces ensured that this soon became an easy slide by hand.

All hands on the connecting rod!

Tony, Richard and Malcolm ease the rod in.

Inserting the left hand connecting rod (small end) into the crosshead.

Connecting rod big end being secured.

The final job is to pin it!

The pin located.

A job well done!

Malcolm, Dennis, Martin, Tony and Mike after a hard (but rewarding) day's work