Wilesco D10

Restoration

6-12-2009

Today my wilesco D10 arrived directly from ebay. These pictures are the state it was in when I got it.... I sure have my work cut out for me...

This was the burner slide tray, I was lucky to even get it out of the engine...

The Cylinder assembly wasn't too bad, it just needs lots of oil, and It' s missing the governer. (notice the toothbrush in the background ;)

 Now that's why the burner tray was stuck...

This is the whistle, and, wouldn' t you know it, it's stuck shut. The  boiler thread is also stuck to the whistle thread. That could be a problem... well, if the thread was in that condition and the whistle came out I would have a real problem on my hands when I fire it. 0_O

The safety valve... at least it came loose. The seal is crusted to the thread though. Armed with some barkeepers friend, vineagar, and a toothbrush, I started with the overall dust. Scrubbing that off with the toothbrush was very very tedious, so I took it outside and sprayed it off with the garden hose. I would not recommend doing so If you have an engine with a decal on it, or one with paint that you don't want to damage. Mine was missing all decals and was just a junker I  wasn't really worried about.

Here I took the boiler sight glass off. On the backside, the bolts were rusted in, and I had to pry those off so they wouldn' t come loose later and get lost.... Luckily, the interior of the boiler isn't too bad.

Unfortunately, this is the only before picture I got of the state of the firebox. This is my first restore, and this is a learning experience, but believe me, it was really rusted. On the inside, there were these little orange spots of rust that came off easily.


6-13-2009

After thinking about it for a long time, I decided to remove the boiler and firebox for cleaning.  The tabs were so rusty I was worried about breaking them. After cleaing the firebox, I got some rust off (mostly the orange spots) but not much changed in the photo above. I got the inside clean, but the outside was quite stubborn and I didn' t want to risk the original paint, so all that came off was the dust, some paint, and minor rust. The boiler was hard to get off.

This tab was holding the boiler onto the firebox. It was so rusted to the metal, I took a screwdriver and put it under the tab. It could not be pried off, so I started pounding on the screwdriver and eventually got under it enough so I could pry it up. (be careful when trying this, because if the firebox is not padded correctly, It will bend itself out of shape when you pound it.)

Just another view of how the tab attaches  to the boiler. (this was taken after I cleaned the boiler, metal tab, and firebox.)

I don't have a picture for this, but the bottom of the boiler was completely black with ash and soot. Once it was out, I soaked it in barkeepers friend along with that metal tab, the slide tray guide, the burner tray, the whistle, and the safety valve.


 6-15-2009

last night, I took the whistle and safety valve out of the barkeepers friend, and put them in vineagar. I got impatient with the whistle, and took it out, scrubbed it (it shined up really well), put some WD-40 in the joint, then waited about 5 seconds. With my pliers, I then tried opening the joint with force. That didn't work out so well, and I broke the whistle. The thread was also still stuck to the whistle, so I started chiseling away at the crusty seal. Once I was a sufficient way through, I took some other pliers, clamped onto the flat surface at the bottom of the whistle, and when I tried turning the thread, It came out beautifully. So, this morning, I scrubbed off  everything. The boiler turned out beautifully except where rust had eaten away at the nickel plating. And the burner tray now fits into it' s guide and looks much much better.

Whistle, shiny but broken.

Safety valve, shiny and not broken!

The burner tray cleaned up quite well, and fits into the guide much nicer now.


6-17-2009

When I got impatient with two limescale spots on the back of the boiler, I decided to put it in some vinegar. Unfortunately, it dissolved some of the nickel plating, leaving a ring around the boiler at the level of the vineagar. it also left some black residue on the bottom that will not come off.

There's the ugly ring.

And there's the residue.


6-20-2009

After having the dissasembled steam engine sitting around for three days, I finally ordered the new parts.


6-22-2009

The spare parts shipped today!


6-24-2009

The parts just arrived, so I went over to my neighbor so we could repair the thread. He couldn't find the tip for his blowtorch, so he just sanded down my shoddy soldering joint so I could get a good seal. Then, I reassembled everything and tried to steam it that night. It was too late, so we called it off.

doesn't  it look great :)


6-25-2009

This morning I did a pressure test, and discovered a leak around the whistle. I was trying to take the whistle off so I could seal it properly, when the thread came off... again... Turns out, the sanding job removed lots of solder connecting the thread to the boiler, and thinned the solder that was left. Plus, since it was just soldered with a normal soldering iron, it didn't sink in to around the thread. Now I hope to get ahold of my neighbor so we can fix the thread properly.

 Here you can clearly see the newly patched thread came out with the whistle :(


6-26-2009

Yesterday, I consulted with my neighbor, and since his torch is broken, he recommended some JB weld. After I looked at the instructions, my worries were calmed with their claims of a tensile strength of about 4000 psi, and a maximum temperature of 600 degrees. After I mixed it up, I just lined the inside of the thread hole, and the outside of the thread with JB weld, put it back in, and it perfectly lined the inside, bonded with the existing solder, and left no visible signs on the outside. So, this morning, after the obligatory 15 hours, I reassembled the entire thing, I steamed it!

IT LIVES!

Barely

I just steamed it, and after about seven minutes (using about 1 esbit tablet) the piston began to move of it's own accord, but wouldn't start. While I was spinning it, it spit an oily, watery, yellow substance at me. Then, almost two minutes later, it started moving when I spun it. Unlike normal, where it gets up to crazy fast speed. Mine went at a walking pace, and never got above that. It stayed at that speed until the fuel started to die out, but during that entire time, it spit oil/water condensate out of the exhaust pipe. The second run was exactly the same, except slower, and the condensate was clearer.

There's the  stuff it was spitting, in the condensate tray.


7-9-2009

Today it ran perfectly! After I cleaned out the excess oil (last time I over oiled it x10) and put the right amount of fuel in, It took off! It fell apart on the first run, but I was beside myself! So this didn't matter.

This video started about halfway through the run when I realized my camera was right next to me.


The fuel was running low, so I refilled and went again!


When I got bored, I decided to add some music to part two of my first steaming. 


At the suggestion of my fellow steamers, I built myself an acessory out of knex, and this is my D10 running it! 


And thus ends my very first restoration of a Wilesco D10!


10-22-2009

As this engine hasn't been run in a long time, I ran it! I used the meths burner from my MM1 that Glenn made for me in it as the solid fuel STINKS!

I ran this engine for a solid hour! fill the meths, fill the boiler, fill the meths, and so on and so forth! boy was it fun! 


Before + After

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